U.S. patent number 10,995,481 [Application Number 16/289,701] was granted by the patent office on 2021-05-04 for toilet with overflow protection.
This patent grant is currently assigned to Delta Faucet Company. The grantee listed for this patent is Delta Faucet Company. Invention is credited to Derek Allen Brown, Garry Robin Marty, Robert W. Rodenbeck, Kurt Judson Thomas, Michael J. Veros.
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United States Patent |
10,995,481 |
Veros , et al. |
May 4, 2021 |
Toilet with overflow protection
Abstract
A flush toilet includes a bowl, a tank coupled to the bowl, a
flush valve positioned within the tank, and a flush device
configured to initiate a flush cycle. The automatic toilet further
comprises an electronic sensing assembly having a sensing member
positioned on the bowl for detecting an overflow condition of the
bowl, an overflow device operably coupled to the flush device, and
a controller in electronic communication with the electronic
sensing assembly and the overflow device for controlling the flush
device in response to a condition of the toilet.
Inventors: |
Veros; Michael J. (Carmel,
IN), Thomas; Kurt Judson (Indianapolis, IN), Rodenbeck;
Robert W. (Indianapolis, IN), Marty; Garry Robin
(Fishers, IN), Brown; Derek Allen (Lizton, IN) |
Applicant: |
Name |
City |
State |
Country |
Type |
Delta Faucet Company |
Indianapolis |
IN |
US |
|
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Assignee: |
Delta Faucet Company
(Indianapolis, IN)
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Family
ID: |
1000005529140 |
Appl.
No.: |
16/289,701 |
Filed: |
March 1, 2019 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20190264434 A1 |
Aug 29, 2019 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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15818887 |
Nov 21, 2017 |
10221554 |
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14384923 |
Dec 5, 2017 |
9834918 |
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PCT/US2013/030952 |
Mar 13, 2013 |
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61610205 |
Mar 13, 2012 |
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61722074 |
Nov 2, 2012 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E03D
5/105 (20130101); E03D 1/00 (20130101); E03D
5/026 (20130101) |
Current International
Class: |
E03D
5/10 (20060101); E03D 1/00 (20060101); E03D
5/02 (20060101) |
References Cited
[Referenced By]
U.S. Patent Documents
Other References
International Search Report and Written Opinion dated May 21, 2013,
from the International Search Authority in priority application No.
PCT/US2013/030952. cited by applicant.
|
Primary Examiner: Loeppke; Janie M
Attorney, Agent or Firm: Bose McKinney & Evans LLP
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a continuation of U.S. patent
application Ser. No. 15/818,887, filed Nov. 21, 2017, now U.S. Pat.
No. 10,221,554, which is a continuation of U.S. patent application
Ser. No. 14/384,923, filed Sep. 12, 2014, now U.S. Pat. No.
9,834,918, which is a 371 national phase filing of International
Patent Application No. PCT/US2013/030952, filed Mar. 13, 2013,
which claims the benefit of U.S. Provisional Patent Application
Ser. No. 61/610,205, filed on Mar. 13, 2012, and U.S. Provisional
Patent Application Ser. No. 61/722,074, filed on Nov. 2, 2012, the
complete disclosures of which are expressly incorporated by
reference herein.
Claims
The invention claimed is:
1. A toilet, comprising: a bowl; a tank coupled to the bowl; a
flush valve positioned within the tank; a handle assembly
configured to initiate a flush cycle and positioned at least
partially outward of the tank, and the handle assembly includes a
handle member and a lever arm; a clutch mechanism configured to
operate the handle assembly and positioned inside the tank, the
clutch mechanism has a first clutch plate and a second clutch plate
operably coupled to the first clutch plate, and the lever arm is
positioned adjacent at least one of the first or second clutch
plates; an electronic sensing assembly having a sensing member
positioned on the bowl for detecting an overflow condition of the
bowl; an overflow device operably coupled to the flush valve; and a
controller in electronic communication with the electronic sensing
assembly and the overflow device for controlling the flush valve in
response to a condition of the toilet.
2. The toilet of claim 1, wherein the first clutch plate includes
detents configured to frictionally mate with detents of the second
clutch plate.
3. The toilet of claim 1, wherein the second clutch plate includes
a channel angled relative to a rotational axis of the handle
assembly.
4. The toilet of claim 3, wherein the channel is perpendicular to
the rotational axis.
5. The toilet of claim 3, wherein the lever arm is operably coupled
to the flush valve and the lever arm is received within the
channel.
6. The toilet of claim 1, wherein the lever arm is operably coupled
to the flush valve and configured to be directly coupled to the
handle member along an axis of rotation of the handle assembly.
7. The toilet of claim 6, wherein the handle assembly further
comprises a blocking assembly configured to prevent rotation of the
handle member when an overflow condition is sensed by the
electronic sensing assembly.
8. The toilet of claim 1, wherein the flush valve has a flapper
configured to move between an open position wherein water flows
into the bowl from the tank and a closed position wherein water
remains in the tank, the flapper being operably coupled to the
handle to move the flapper to the open position.
9. The toilet of claim 1, wherein the lever arm is received within
an opening of the at least one of the first or second clutch
plates.
10. An automatic flush toilet, comprising: a bowl; a tank coupled
to the bowl and supporting a quantity of water; a fill valve
assembly positioned in the tank and including at least one
electrically-operable valve assembly; a flush actuator assembly
fluidly coupled to the fill valve assembly; a water supply in fluid
communication with the fill valve assembly; a flush valve assembly
having a flapper configured to move between an open position
wherein water flows into the bowl from the tank and a closed
position wherein water remains in the tank, the flapper being
operably coupled to the flush actuator assembly to move the flapper
to the open position; a housing supported by the tank, and the
flush actuator assembly and the fill valve assembly are supported
by the housing; and an overflow device in communication with the at
least one electrically operable valve assembly, wherein the
overflow device is configured to prevent water from the water
supply from entering the tank, and the overflow device is
configured to retain the flapper in the closed position.
11. The toilet of claim 10, wherein a pressure applied to the flush
actuator assembly for operating the flush valve assembly is
constant.
12. The toilet of claim 10, wherein the fill valve assembly defines
an upper portion of the housing and the flush actuator assembly is
supported by a lower portion of the housing.
13. The toilet of claim 10, wherein the housing is at least
partially vertically aligned with the flapper.
14. The toilet of claim 10, further comprising: a handle assembly
configured to initiate a flush cycle and positioned at least
partially outward of the tank; and a clutch mechanism configured to
operate the handle assembly and positioned inside the tank.
15. The toilet of claim 14, wherein the clutch mechanism has a
first clutch plate and a second clutch plate operably coupled to
the first clutch plate.
16. The toilet of claim 15, wherein the first clutch plate includes
detents configured to frictionally mate with detents of the second
clutch plate.
17. The toilet of claim 15, wherein the second clutch plate
includes a channel angled relative to a rotational axis of the
handle assembly.
18. The toilet of claim 15, wherein the handle assembly includes a
handle member and a lever arm, the lever arm is operably coupled to
the flush valve and configured to be directly coupled to the handle
member along an axis of rotation of the handle assembly.
Description
BACKGROUND AND SUMMARY OF THE INVENTION
The present invention relates generally to an automatic flush
toilet and, more particularly, to a hands-free toilet with overflow
prevention.
Conventional toilets include a flush lever on the outside of the
tank to activate the flush mechanism of the toilet. More
particularly, conventional toilets may require the user to depress,
or otherwise move, the flush lever in order to initiate the flush
mechanism. However, some users may be concerned about germs and,
therefore, may feel uncomfortable touching the flush lever.
Additionally, the handles on conventional toilets may allow a user
to successively flush the toilet. However, during certain
conditions of the toilet, such as an overflow condition (e.g., a
blockage in the trapway), it may not be desirable to flush the
toilet.
It is also known that pressure in water supply lines may vary
between installations. For example, the water pressure from a
municipality water source may be greater than the water pressure
from a well water source. Additionally, when multiple water devices
(e.g., washing machines, showers, or sprinklers) are simultaneously
operating at the same location, the water pressure available to any
of these water devices may decrease. When the water pressure
decreases, it may be difficult and time-consuming to operate
certain water devices. Conversely, if the water pressure increases
significantly, there may be damage to the water devices.
According to an illustrative embodiment of the present disclosure,
an automatic flush toilet comprises a bowl, a tank coupled to the
bowl, a flush valve positioned within the tank, and a flush
actuator operably coupled to the flush valve. The flush actuator
includes a piston and a cylinder. The automatic toilet further
comprises an electronic sensing assembly in communication with the
flush actuator, an overflow device in communication with the flush
actuator, and a controller in electronic communication with the
electronic sensing assembly and the overflow device for controlling
the flush actuator.
According to a further illustrative embodiment of the present
disclosure, an automatic flush toilet comprises a bowl, a tank
positioned above the bowl, and a flush actuator assembly positioned
within the tank. The flush actuator assembly is in fluid
communication with a water supply and is configured to receive a
flow of water from the water supply. The toilet also comprises a
flush valve assembly operably coupled to the flush actuator
assembly and an overflow assembly operably coupled to the flush
actuator assembly. The overflow assembly is configured to engage
the flush actuator assembly when a water level in the bowl is above
a predetermined level. The flush actuation assembly is configured
to engage the flush valve assembly to initiate a flush cycle of the
toilet when the water level in the bowl is below the predetermined
level. The flush actuator assembly is activated by a water pressure
during the engagement with the flush valve assembly, and the
pressure activating the flush actuator assembly is constant and
independent of a water pressure in the water supply.
According to another illustrative embodiment of the present
disclosure, an automatic flush toilet comprises a bowl, a tank
coupled to the bowl, and a flush actuator positioned within the
tank. The automatic toilet further comprises a waterway assembly in
fluid communication with the flush actuator, and at least one
electrically operable valve assembly in fluid communication with
the waterway assembly. Additionally, the automatic toilet includes
a flush actuation sensor operably coupled to the at least one
electrically operable valve assembly, and an overflow device in
communication with the at least one electrically operable valve
assembly.
According to yet another illustrative embodiment of the present
disclosure, an automatic flush toilet comprises a bowl, a tank
coupled to the bowl, and a flush valve having a pivotable lever arm
positioned within the tank. The automatic toilet further comprises
a flush actuator having a piston, a cylinder, and a diaphragm. The
flush actuator may be operably coupled to the flush valve.
Additionally, the automatic toilet comprises a waterway assembly in
fluid communication with the flush actuator. The waterway assembly
includes an inlet and at least one outlet. The automatic toilet of
the present disclosure also comprises an electrically operable
valve in fluid communication with the waterway assembly. The
electrically operable valve may be configured to control a flow of
water from the inlet of the waterway assembly to the flush
actuator. The flush actuator is operable by pressure from the flow
of water. Additionally, the automatic toilet comprises a capacitive
sensor in electronic communication with the electrically operable
valve and is configured for hands-free operation of the toilet.
Also, the automatic toilet may comprise an electronic overflow
sensor configured to detect an overflow condition.
According to an illustrative embodiment of the present disclosure,
a flush toilet comprises a bowl, a tank coupled to the bowl, a
flush valve positioned within the tank, and a flush device
configured to initiate a flush cycle. The toilet further comprises
an electronic sensing assembly having a sensing member positioned
on the bowl for detecting an overflow condition of the bowl, an
overflow device operably coupled to the flush device, and a
controller in electronic communication with the electronic sensing
assembly and the overflow device for controlling the flush device
in response to a condition of the toilet.
According to another illustrative embodiment of the present
disclosure, an automatic flush toilet comprises a bowl, a tank
coupled to the bowl, a flush actuator positioned within the tank,
and a water supply in fluid communication with the flush actuator.
The automatic toilet further comprises at least one
electrically-operable valve assembly in fluid communication with
the water supply, a housing for supporting the at least one
electrically-operable valve assembly, and a sensor operably coupled
to the at least one electrically operable valve assembly.
Additionally, the automatic toilet comprises an overflow device in
communication with the at least one electrically operable valve
assembly, wherein the at least one electrically-operable valve
assembly is integral with the housing.
According to yet another illustrative embodiment of the present
disclosure, an automatic flush toilet comprises a bowl, a tank
coupled to the bowl, and a flush actuator positioned within the
tank. The toilet further comprises at least one
electrically-operable valve assembly in fluid communication with
the water supply, and a chainless flush valve assembly in fluid
communication with the electrically-operable valve assembly. The
chainless flush valve assembly has a manual member configured for
manually flushing the toilet. Additionally, the toilet comprises an
overflow device in communication with the electrically operable
valve assembly to control the flush actuator in response to a
condition of the toilet.
An automatic flush toilet comprising a bowl, a tank coupled to the
bowl and supporting a quantity of water, and a fill valve assembly
positioned in the tank and including at least one
electrically-operable valve assembly. The toilet further comprising
a flush actuator fluidly coupled to the fill valve assembly and a
water supply in fluid communication with the flush actuator. The
toilet also comprises a flush valve assembly having a flapper
operably coupled to the flush actuator to move the flapper between
an open position and a closed position. Water flows into the bowl
from the tank in the open position and water remains in the tank in
the closed position. Additionally, the toilet comprises an overflow
device in communication with the at least one electrically operable
valve assembly. The overflow device is configured to prevent water
from the water supply from entering the tank, and the overflow
device is configured to retain the flapper in the closed
position.
Additional features and advantages of the present invention will
become apparent to those skilled in the art upon consideration of
the following detailed description of the illustrative embodiment
exemplifying the best mode of carrying out the invention as
presently perceived.
BRIEF DESCRIPTION OF THE DRAWINGS
The detailed description of the drawings particularly refers to the
accompanying Figures in which:
FIG. 1 is a side perspective view of an illustrative embodiment
toilet of the present disclosure;
FIG. 2 is a side elevational view of the toilet of FIG. 1;
FIG. 3 is an exploded perspective view of the toilet of FIG. 1;
FIG. 4 is a rear view of the toilet of FIG. 1;
FIG. 5 is a rear view of a base of the toilet and an illustrative
mounting assembly of the present disclosure;
FIG. 6 is a rear cross-sectional view of the base and mounting
assembly coupled to a drain, taken along line 6-6 of FIG. 2;
FIG. 7 is a side cross-sectional view of a toilet bowl coupled to a
tank with an illustrative mounting bracket of the present
disclosure, taken along line 7-7 of FIG. 4;
FIG. 8 is a rear perspective view, in cross-section, of the tank of
the toilet, illustrating a fill valve assembly and flush valve
assembly positioned within the tank;
FIG. 9 is a perspective view of the fill valve assembly, the flush
valve assembly, and an overflow assembly of the present
disclosure;
FIG. 10 is a cross-sectional view of the fill valve assembly and a
portion of the flush valve assembly, taken along line 10-10 of FIG.
9;
FIG. 11 is a cross-sectional view of the flush valve assembly in a
closed position illustrating an initial stage of a flush cycle of
the toilet of the present disclosure;
FIG. 12 is a cross-sectional view of the flush valve assembly in an
initial open position, illustrating the flush cycle after the flush
valve assembly has been open opened;
FIG. 13 is an additional cross-sectional view of the flush valve
assembly in the open position, illustrating a later stage of the
flush cycle;
FIG. 14 is a cross-sectional view of the flush valve assembly in
the open position, illustrating a lever arm at full travel during
the flush cycle;
FIG. 15 is a cross-sectional view of the flush valve assembly,
illustrating the lever arm pivoting downwardly to close the flush
valve assembly;
FIG. 16 is a cross-sectional view of the flush valve assembly in
the closed position at a further stage of the flush cycle;
FIG. 17 is a cross-sectional view of the flush valve assembly at
the end of the flush cycle;
FIG. 18A is a cross-sectional view of an electrically operable
valve assembly in a closed position;
FIG. 18B is a cross-sectional view of the electrically operable
valve assembly in an open position; and
FIG. 19 is a diagrammatic view of various operating components of
the toilet of FIG. 1, illustrating a plurality of inputs and
outputs relative to a controller.
FIG. 20 is a front perspective view of an illustrative alternative
embodiment toilet of the present disclosure;
FIG. 21 is a rear view of the toilet of FIG. 20;
FIG. 22 is a front perspective view of a fill valve assembly, a
flush valve assembly, an overflow assembly, and a housing for
electrical components supported by a tank of the toilet of FIG.
20;
FIG. 23 is a perspective view of the fill valve assembly, the flush
valve assembly, and the overflow assembly of FIG. 22;
FIG. 24 is an exploded view of the fill valve assembly, the flush
valve assembly, and the overflow assembly of FIG. 23;
FIG. 25A is a cross-sectional view of an electrically-operable
valve assembly of the fill valve assembly of FIG. 24 in a closed
position;
FIG. 25B is a cross-sectional view of the electrically-operable
valve assembly of the fill valve assembly of FIG. 25A in an open
position;
FIG. 26 is an exploded view of an outlet tube, a plunger, and a
tank refill tube of the fill valve assembly of FIG. 24;
FIG. 27 is a cross-sectional view of the outlet tube, the plunger,
and the tank refill tube of FIG. 26, taken along line 27-27 of FIG.
26;
FIG. 28 is a cross-sectional view of the fill valve assembly of
FIG. 23 and a flush actuator assembly, taken along line 28-28 of
FIG. 23;
FIG. 29 is a cross-sectional view of the flush valve assembly of
FIG. 23;
FIG. 30 is a front perspective view of the housing for electrical
components of FIG. 22;
FIG. 31 is a rear exploded view of the housing of FIG. 30;
FIG. 32 is a cross-sectional view of the housing of FIG. 30, taken
along line 32-32 of FIG. 30;
FIG. 33 is a cross-sectional view of the flush valve assembly in a
closed position, taken along line 33-33 of FIG. 23, illustrating an
initial stage of a flush cycle of the toilet of the present
disclosure;
FIG. 34 is a cross-sectional view of the flush valve assembly of
FIG. 33 in an initial open position, illustrating the flush cycle
after the flush valve assembly has been open opened;
FIG. 35 is an additional cross-sectional view of the flush valve
assembly of FIG. 33 in the open position, illustrating a later
stage of the flush cycle;
FIG. 36 is a cross-sectional view of the flush valve assembly of
FIG. 33 in the open position, illustrating a lever arm at full
travel during the flush cycle;
FIG. 37 is a cross-sectional view of the flush valve assembly of
FIG. 33, illustrating the lever arm pivoting downwardly to close
the flush valve assembly;
FIG. 38 is a cross-sectional view of the flush valve assembly of
FIG. 33 in the closed position at a further stage of the flush
cycle;
FIG. 39 is a cross-sectional view of the flush valve assembly of
FIG. 33 at the end of the flush cycle;
FIG. 40 is a diagrammatic view of various operating components of
the toilet of FIG. 20, illustrating a plurality of inputs and
outputs relative to a controller;
FIG. 41 is a front perspective view of an alternative embodiment of
the overflow assembly of FIG. 22, including a handle assembly
coupled to a tank and having a blocking pin assembly;
FIG. 42A is a front exploded view of the alternative embodiment
handle assembly of FIG. 41;
FIG. 42B is a rear exploded view of the handle assembly of FIG.
42A;
FIG. 42C is a rear exploded view of a handle and a coupler of the
handle assembly of FIG. 42B;
FIG. 43 is a cross-sectional view of the handle assembly of FIG.
41, taken along line 43-43 of FIG. 41, in an overflow position;
FIG. 44 is a cross-sectional view of the handle assembly of FIG. 43
in a flush position;
FIG. 45 is a front perspective view of an alternative embodiment of
the handle assembly of FIG. 41, including an alternative embodiment
of the blocking pin assembly;
FIG. 46 is a front exploded view of the alternative embodiment
handle assembly of FIG. 45;
FIG. 47 is a rear exploded view of the handle assembly of FIG.
45;
FIG. 48 is a top cross-sectional view of the handle assembly of
FIG. 45, taken along line 48-48 of FIG. 45, in a flush
position;
FIG. 49 is a top cross-section view of the handle assembly of FIG.
48 in an overflow position;
FIG. 50 is a side perspective view of an alternative embodiment of
the handle assembly of FIG. 45, including a clutch assembly;
FIG. 51A is front exploded view of the alternative embodiment
handle assembly of FIG. 50;
FIG. 51B is a rear exploded view of the alternative embodiment
handle assembly of FIG. 51A;
FIG. 52 is a top cross-sectional view of the handle assembly of
FIG. 50, taken along line 52-52 of FIG. 50, in an overflow
position;
FIG. 53 is a top cross-sectional view of the handle assembly of
FIG. 52 in a flush position;
FIG. 54 is an exploded view of another illustrative alternative
embodiment toilet of the present invention;
FIG. 55 is a rear perspective view of a fill valve assembly, a
flush valve assembly, and an overflow assembly of the toilet of
FIG. 54 within a tank;
FIG. 56 is a rear view of the fill valve assembly, the flush valve
assembly, and the overflow assembly of FIG. 55 within the tank;
FIG. 57 is an exploded view of the fill valve assembly of FIG.
56;
FIG. 58 is a rear cross-sectional view of the fill valve assembly,
the flush valve assembly, and the overflow assembly within the
tank;
FIG. 59 is a rear cross-sectional view of the fill valve assembly
of FIG. 57;
FIG. 60 is a side cross-sectional view of the fill valve assembly
of FIG. 57;
FIG. 61 is a diagrammatic view of various operating components of
the toilet of FIG. 54, illustrating a plurality of inputs and
outputs relative to a controller; and
FIG. 62 is a diagrammatic view of the flow path of the water
through toilet 1510.
DETAILED DESCRIPTION OF THE DRAWINGS
The embodiments of the invention described herein are not intended
to be exhaustive or to limit the invention to precise forms
disclosed. Rather, the embodiments selected for description have
been chosen to enable one skilled in the art to practice the
invention. Although the disclosure is described in connection with
water, it should be understood that additional types of fluids may
be used.
Referring to FIGS. 1-3, an illustrative embodiment toilet 10 is
shown including a waterway assembly 20, a mounting base 30, a
mounting assembly 40, a bowl 60, a tank 70, a flush valve assembly
80, a fill valve assembly 130, and an overflow assembly 150.
Illustratively, toilet 10 is a tank-type, gravity-fed toilet.
Alternatively, other embodiments of toilet 10 may be contemplated.
In operation, water from tank 70 flows into bowl 60 in order to
flush toilet 10 and remove the contents of bowl 60.
As shown in FIGS. 3 and 4, waterway assembly 20 includes an inlet
waterway 20a and an outlet waterway 20b. In particular, inlet
waterway 20a may include a supply tube 22, and outlet waterway 20b
may include an outlet tube, illustratively a siphon tube or trapway
24, a drain tube 26 (FIG. 6), at least one seal 28, and a drain
flange 29 (FIG. 6). Outlet waterway 20b may be of conventional
design. Waterway assembly 20 may also include additional sealing
members (not shown) and additional mounting hardware (not shown).
To limit contact between the water in toilet 10 and metallic
components, waterway assembly 20 may be formed of a non-metallic
material, such as a polymer, illustratively a cross-linkable
polymer. Alternatively, waterway assembly 20 may be lined with a
non-metallic material. As such, waterway assembly 20 is
illustratively electrically non-conductive.
As shown in FIG. 9, supply tube 22 of inlet waterway assembly 20a
may be in fluid communication with flush valve assembly 80 and
overflow assembly 150 through fill valve assembly 130. In
particular, supply tube 22 is fluidly coupled to a water supply
(not shown) in order to flow water into fill valve assembly 130, as
is further detailed herein.
Referring to FIGS. 3 and 6, trapway 24 of outlet waterway assembly
20b is illustratively curved and is coupled to bowl 60 and drain
tube 26 (FIG. 6). More particularly, trapway 24 is intermediate
bowl 60 and drain tube 26, such that the contents of bowl 60 flow
through trapway 24 and into drain tube 26. Drain tube 26 connects
trapway 24 to a main sewer line (not shown) to carry away the
contents of bowl 60.
As shown in FIG. 6, drain tube 26 of outlet waterway supply 20b may
be coupled to trapway 24 and floor 2 through a drain flange 29 and
seal 28. Drain flange 29 is positioned on an upper surface of floor
2 and is intermediate floor 2 and base 30. Drain flange 29 receives
drain tube 26 and an adhesive, epoxy, or other similar material may
be used to couple to drain tube 26 to drain flange 29. Seal 28 is
positioned between drain tube 26 and base 30 to prevent water
leakage. At least a portion of seal 28 is in sealing engagement
with drain flange 29. Illustratively, seal 28 may extend along the
top surface of drain flange 29. Seal 28 may be comprised of a
polymeric or wax material, for example beeswax, rubber, and other
similar materials.
The illustrative mounting base 30 of toilet 10 is a pedestal-type
configured to rest atop floor 2. Mounting base 30 supports tank 70
and bowl 60 above floor 2. As shown in FIG. 2, tank 70 is supported
by a rear portion 32 of base 30 and bowl 60 is supported by a front
portion 34 of base 30. In the illustrative embodiment, base 30
integrally supports trapway 24 of waterway assembly 20.
Illustratively, base 30 is a concealed-trapway type in that trapway
24 is hidden from view by sidewalls 38 of base 30 (FIG. 3). Base 30
may be comprised of a ceramic, metal, or polymeric material. For
example, base 30 may be comprised of porcelain, stainless steel, or
plastic composite materials.
Referring to FIGS. 4-6, mounting assembly 40 couples base 30 to
drain tube 26. In particular, mounting assembly 40 couples base 30
to drain flange 29 with fasteners, illustratively bolts 42 and nuts
44. Bolts 42 extend through apertures 45 in drain flange 29 to
couple base 30 thereto. Illustratively, a threaded end 42a of each
bolt 42 extends upwardly from below drain flange 29 in order to
receive nuts 44 (FIG. 6). It may be appreciate that bolts 42 and
nuts 44 are not visible to a user because base 30 is a
concealed-trapway type.
Still referring to FIGS. 4-6, mounting assembly 40 also may couple
base 30 to drain tube 26 with brackets 50. More particularly,
brackets 50 may be positioned within slots 36 of base 30 and
positioned above drain flange 29. Illustratively, brackets 50
include a first bracket 50a and a second bracket 50b. Brackets 50a,
50b are generally opposite each other such that trapway 24 is
intermediate brackets 50a, 50b. Brackets 50a, 50b each may include
angled or inclined portions 52 having a plurality of apertures 58
(FIG. 5). As shown in FIG. 3, brackets 50a, 50b may be
L-shaped.
Brackets 50a, 50b also may be coupled to drain flange 29 with bolts
42. For example, bolts 42 extend through apertures 45 in drain
flange 29 and through apertures 51 in brackets 50a, 50b in order to
secure base 30 to drain flange 29. Washers 56 may be positioned
between brackets 50a, 50b and nuts 44.
In addition to being coupled to drain flange 29, brackets 50a, 50b
also may be coupled to base 30. As shown in FIGS. 4-6, inclined
portions 52 generally extend upwardly and inwardly toward bowl 60.
In particular, inclined portions 52 may be angled inwardly and away
from the bottom of base 30. Apertures 58 of inclined portions 52
illustratively arranged in two columns. Apertures 58 may be
internally threaded in order to receive a screw 54 from outside of
base 30, thereby coupling base 30 to brackets 50a, 50b. The
position of screw 54 is sufficiently aligned with one of apertures
58 in base 30 in order to receive screw 54 therethrough. Additional
mounting hardware, such as end caps 59, also may be included with
mounting assembly 40 in order to conceal screws 54.
Referring to FIGS. 1-3, illustrative bowl 60 is integrally
supported by base 30 and is generally positioned above and forward
of concealed trapway 24. Bowl 60 may be comprised of a ceramic,
metal, or polymeric material. For example, bowl 60 may be comprised
of porcelain, stainless steel, or plastic composite materials. Bowl
60 has a generally elliptical shape and, more particularly, has a
circular shape. A bottom portion of bowl 60 is fluidly coupled to
trapway 24 in a known manner.
As shown in FIGS. 3 and 7, bowl 60 may be mounted to tank 70 with a
mounting bracket 110. Mounting bracket 110 may be comprised of a
metallic or polymeric material. Illustratively, mounting bracket
110 has a generally triangular shape, although mounting bracket 110
may have other shapes (e.g., circular, rectangular). Additionally,
mounting bracket 110 may include a coupling member, illustratively
a hook 111, that engages with supply tube 22 and extends
substantially around supply tube 22 in order to secure supply tube
22 to tank 70 (FIG. 5). Mounting bracket 110 may be positioned
below tank 70 and at least partially within a recessed inlet 68 of
bowl 60. Mounting bracket 110 has a first or upper side 114 that
engages tank 70 and a second or lower side 116 that engages base
30. Mounting bracket 110 also may include apertures 112 that extend
from first side 114 to second side 116 of mounting bracket 110 in
order to couple mounting bracket 110 to bowl 60.
In order to couple mounting bracket 110 to bowl 60, apertures 112
of mounting bracket 110 align with apertures 65 of rear portion 32
of base 30. Conventional fasteners, such as bolts 118 extend
through apertures 112 of mounting bracket 110 and apertures 65 of
base 30, and may threadedly couple with additional fasteners, such
as nuts 120, in order to secure mounting bracket 110 to base 30.
Illustratively, apertures 112 are square, and bolts 118 may be of
the carriage-type, which include a square feature below the head of
bolts 118, in order to prevent rotation of bolts 118 during
assembly with nuts 120. Mounting bracket 110 also may be coupled to
tank 70 through a threaded connection with a flush tube 82 of flush
valve assembly 80. Illustratively, flush tube 82 has a threaded
outer surface that engages with a coupler or other fastener, such
as a nut 122, along second side 116 of mounting bracket 110.
Nut 122 may engage a sealing member 124 to prevent water leakage
between tank 70 and base 30. Additionally, a seal 126 may be
positioned within tank 70 to also prevent water leakage therefrom.
More particularly, seal 126 may bend around an inner surface of
tank 70 to extend at least partially through an outlet aperture 72
of tank 70. Alternatively, mounting bracket 110 may be overmolded
to form a unitary bracket that sealingly engages both base 30 and
tank 70. More particularly, first side 114 of mounting bracket 110
may be integrally formed with seal 126 and second side 116 may be
integrally formed with seal 124 for base 30. Other alternative
embodiments of the present disclosure may integrally couple flush
tube 82 with mounting bracket 110 and seals 124, 126.
Referring to FIGS. 1-4, tank 70 may have a generally rectangular
cross-section, or may be defined by other shapes in cross-section.
Illustratively, tank 70 includes a bottom wall 74 and side walls 76
extending upwardly therefrom. Bottom wall 74 includes outlet
aperture 72 which receives flush tube 82. Additionally, a lid 78
may rest atop walls 76. As with bowl 60 and base 30, tank 70 may be
comprised of a ceramic, metal, or polymeric material. For example,
tank 70 may be comprised of porcelain, stainless steel, or plastic
composite materials.
Tank 70 may include a recessed portion 75 projecting inwardly from
one of sides 76 (FIGS. 3 and 4). Recessed portion 75 is configured
to receive supply tube 22 between the water supply and fill valve
assembly 130. Tank 70 further supports flush valve assembly 80,
fill valve assembly 130, and overflow assembly 150 therein.
As shown in FIGS. 8 and 9, fill valve assembly 130 includes an
inlet 132, a bowl refill outlet 134, a tank refill outlet 136, a
flush actuator outlet 138 (FIG. 10), a valve assembly 140, a
housing 142, and a bowl overflow sensor 226 (FIG. 4).
Illustratively, bowl overflow sensor 226 is coupled to base 30 with
adhesive or other similar materials, which may eliminate the need
for invasive fasteners, such as bolts or screws, which would
penetrate base 30 and form a potential leakage point. Bowl overflow
sensor 226 is configured to detect an overflow condition, such as
when the water level in bowl 60 rises above a predetermined,
critical level, in order to prevent bowl 60 from overflowing. In
particular, bowl overflow sensor 226 may prevent operation of valve
assembly 140 when an overflow condition is detected. Alternatively,
when an overflow condition is not signaled by bowl overflow sensor
226, a controller 230 (FIG. 19) may be used to send a signal to
valve assembly 140 to initiate a flush cycle, as is further
detailed herein. Bowl overflow sensor 226 may be a piezoelectric
element, an infrared sensor, a radio frequency ("RF") device, or a
capacitive sensor, for example.
Housing 142 may include an upper portion 144 and a lower portion
146. Illustratively, upper portion 144 supports inlet 132, outlets
134, 136, 138, and valve assembly 140. Lower portion 146 may be
coupled to flush valve assembly 80 with fasteners 147, such as
screws or bolts. Fill valve assembly 130 may be comprised of a
polymeric material to limit contact between the water and metallic
components. Alternatively, fill valve assembly 130 may be lined
with a non-metallic material. As such, fill valve assembly 130 is
illustratively electrically non-conductive.
Inlet 132 is fluidly coupled with supply tube 22. More
particularly, inlet 132 may include external threads 133 that
couple with a nut 131 to join supply tube 22 thereto. One of side
walls 76 of tank 70 may include an internal support member or
bracket (not shown) to support the connection between supply tube
22 and inlet 132. In particular, the connection between supply tube
22 and inlet 132 may occur within tank 70.
Valve assembly 140 is positioned within housing 142 and is in fluid
communication with inlet 132, bowl refill outlet 134, tank refill
outlet 136, and flush actuator outlet 138. Valve assembly 140 may
be an electrically operable valve, for example an electromechanical
valve, and illustratively is a solenoid valve of the latching-type
having a valve seat 160, a diaphragm 162, a shaped portion 164,
illustratively a V-shaped groove, a pilot hole 166, a seal 168,
o-rings 170, a magnet 172, a pole 174, an armature 176, and a
spring 178, as shown in FIGS. 18A and 18B.
Valve assembly 140 is in electrical communication with controller
230 (FIG. 19). During operation of toilet 10, valve assembly 140
receives signals from controller 230 in order to control the flow
of water from inlet 132 to bowl refill outlet 134, tank refill
outlet 136, and flush actuator outlet 138, as further detailed
herein. More particularly, valve assembly 140 may be actuated by
controller 230 to magnetically attract armature 176 to pole 174,
thereby allowing water from inlet 132 to flow between valve seat
160 and diaphragm 162, and into outlets 134, 136, 138. Valve
assembly 140 may be comprised of polymeric or other electrically
nonconductive materials.
As shown in FIG. 18A, when valve assembly 140 is in the closed
position, diaphragm 162 engages valve seat 160 due to the force
behind diaphragm 162. More particularly, the force behind diaphragm
162 is sufficient to overcome the force at the front of diaphragm
162. The resulting force behind diaphragm 162 is due to water
pressure at opposing front and rear surfaces of diaphragm 162 in
combination with surface area differences between the front and
rear of diaphragm 162. While the pressure at the front and rear of
diaphragm 162 may be equalized (due to water flow through shaped
portions 164), the greater surface at the rear of diaphragm 162
creates a greater force behind diaphragm 162. As such, diaphragm
162 engages with valve seat 160 such that water may not pass
between diaphragm 162 and valve seat 160, thereby preventing water
from flowing into outlets 134, 136, 138.
The force behind diaphragm 162 may be created when armature 176 is
spaced apart from pole 174. A gap 179 may be defined by the space
between armature 176 and pole 174 when valve assembly 140 is in the
closed position. In particular, spring 178 biases armature 176 away
from pole 174 in order to position seal 168 against pilot hole 166.
When pilot hole 166 is sealed, a force is maintained behind
diaphragm 162 to sealingly engage diaphragm 162 with valve seat
160.
However, as shown in FIG. 18B, when valve assembly 140 has been
actuated by controller 230, a short electrical pulse is provided in
order to move armature 176 toward pole 174. When the electrical
pulse is discontinued, armature 176 will remain latched to, or
otherwise in contact with, pole 174 due to a magnetic attraction to
magnet 172. This magnetic force is sufficient to overcome the bias
in spring 178 to allow armature 176 to move toward pole 174 and
close gap 179. When armature 176 contacts pole 174, seal 168 moves
with armature 176 and is pulled away from pilot hole 166, which
creates a pressure and force differential in valve assembly 140. In
particular, the pressure behind diaphragm 162 is reduced because
pilot hole 166 is no longer sealed. As such, diaphragm 162 may
flex, bend, or otherwise move in response to the force from the
water at inlet 132. As such, water may flow between diaphragm 162
and valve seat 160 in order to flow into outlets 134, 136, 138.
When it is necessary to close valve assembly 140, a short
electrical pulse is provided in order to generate a magnetic force
opposite that of magnet 172. The opposing magnetic force unlatches
armature 176 from pole 174 in order to move armature 176 toward
seal 168. Spring 178 facilitates the movement of armature 176
toward seal 168 because the electrical pulse has a short duration,
for example 25 milliseconds.
The illustrative embodiment of fill valve assembly 130 includes
outlets 134, 136, 138, however, any number of outlets may be
included to accommodate particular applications of fill valve
assembly 130. Bowl refill outlet 134 may be integrally formed with
housing 142 and extend from housing 142. Illustratively, bowl
refill outlet 134 may be generally positioned within housing 142
adjacent inlet 132. Additionally, bowl refill outlet 134 may be
fluidly coupled to a bowl refill tube 149, which illustratively
extends from bowl refill outlet 134 to an overflow tube 152 of
overflow assembly 150. Bowl refill tube 149 may be smaller in
diameter than overflow tube 152 such that it is conventionally
received therein.
As shown in FIGS. 8 and 9, tank refill outlet 136 may be positioned
within housing 142 adjacent inlet 132, and generally opposite bowl
refill outlet 134. In particular, tank refill outlet 136 may be
integrally formed with housing 142 to extend outwardly from housing
142. Tank refill outlet 136 is fluidly coupled a tank refill tube
139. Tank refill tube 139 extends downwardly from tank refill
outlet 136 and may be positioned near bottom wall 74 of tank 70. As
such, the position of tank refill tube 139 may prevent water
splashing and a user from hearing the water from tank refill tube
139 contacting bottom wall 74 of tank 70 when tank 70 is being
refilled.
Flush actuator outlet 138 may be a conduit extending from housing
142 to flush valve assembly 80. In this way, fill valve assembly
130 is fluidly coupled to flush valve assembly 80 through flush
actuator outlet 138.
Referring to FIGS. 8-10, flush valve assembly 80 includes flush
tube 82, flush valve flapper 84, a flush actuator assembly 86, an
indicator 88, and a flush actuation sensor 234 (FIG. 19). Flush
actuation sensor 234 cooperates with indicator 88 (FIG. 8) and
controller 230 (FIG. 19) in order to initiate a flush cycle.
Indicator 88 may be coupled to tank 70 and extend therefrom, as
shown in FIG. 8. More particularly, indicator 88 and controller 230
may be coupled to the same side wall 76 of tank 70 such that side
wall 76 of tank 70 is intermediate flush indicator 88 and
controller 230. Illustratively, controller 230 may be positioned
within a waterproof box or casing 224 in tank 70 (FIG. 8). Casing
224 may also house at least one battery 232 (FIG. 19) in order to
supply power to controller 230. Additionally, other electronic
components may be housed within casing 230. Alternatively,
indicator 88 may include a sensor electrically coupled to
controller 230.
Flush actuation sensor 234 may be a piezoelectric element, an
infrared sensor, a radio frequency ("RF") device, a mechanical
latching switch, or a capacitive sensor, for example. Flush
actuation sensor 234 is configured to receive a user input and is
in electronic communication with controller 230 (FIG. 19). In one
illustrative embodiment, flush actuation sensor 234 may be a
capacitive sensor, using touch or hands-free proximity sensing. By
incorporating capacitive sensing into toilet 10, a single microchip
may be used to electrically communicate with flush actuation sensor
234, bowl overflow sensor 226, and a tank fill sensor 154 (FIG. 9).
Additionally, capacitive sensing may allow bowl overflow sensor
(FIG. 4) to sense through base 30 without adding holes to base 30.
Furthermore, as is known, capacitive sensing provides for robust
electrical communication and may be less expensive than other
sensing mechanisms.
As shown in FIG. 10, flush actuator assembly 86 may include a
piston assembly 180 coupled to a diaphragm 190 within a cylinder
200. Cylinder 200 includes an upper shoulder 202 that couples with
lower portion 146 of housing 142 through fasteners 147. Shoulder
202 illustratively includes a channel 204 which receives a lip 192
of diaphragm 190. As such, lip 192 of diaphragm 190 is positioned
within channel 204 between shoulder 202 and lower portion 146 of
housing 142. A sealing end 194 of diaphragm 190 may be coupled to
piston assembly 180 with a screw 189. As such, sealing end 194 of
diaphragm 190 may form a seal between piston assembly 180 and lower
portion 146 of housing 142. Illustratively, diaphragm 190 is a
rolling diaphragm and may move with piston assembly 180, as further
detailed herein. Diaphragm 190 may be comprised of a flexible
elastomeric material.
Piston assembly 180 illustratively includes a spring 182, piston
184, a piston rod 186, and a retainer plate 188 coupled to the top
of piston 184 with screw 189 or other fastener. Piston 184 is
coupled to sealing end 194 of diaphragm 190 via retainer plate 188
and screw 189. As such, retainer plate 188 also fluidly seals
piston assembly 180 from housing 142. In operation, water pressure
may be used to engage flush actuator 86. Additionally, a lower
surface of cylinder 200 may include apertures 203 for releasing or
exhausting air from cylinder 200 during operation of flush actuator
assembly 86.
Piston 184 may have a generally round shape that is substantially
hollow (e.g., inverted cup shape). At least a portion of spring 182
and piston rod 186 are illustratively positioned within piston 184.
Piston rod 186 may be coupled to piston 184 via screw 189. Piston
rod 186 extends downwardly from piston 184 and through an aperture
206 in cylinder 200 to extend below cylinder 200. As shown in FIG.
10, piston rod 186 may be selectively coupled to lever arm 100
through a piston lever 102. Piston lever 102 may be pivotably
coupled to piston rod 186 and is configured to selectively engage
lever arm 100.
Lever arm 100 includes a first end 115 and an opposing second end
117. First end 115 is adjacent piston lever 102 and may be in
contact with piston lever 102 during a flush cycle of toilet 10.
Second end 117 is illustratively coupled to flapper 84 through a
chain 208. Chain 208 is positioned within a cylindrical housing 210
and raises and lowers flapper 84 with the movement of lever arm 100
during the flush cycle.
Referring to FIG. 9, flapper 84 of flush valve assembly 80 is
positioned within a frame 212 coupled to housing 210. More
particularly, housing 210 is illustratively coupled to the top of
frame 212. Housing 210 may be configured for rotation relative to
frame 212 in order to accommodate various sizes and spatial
arrangements of tank 70 and waterway assembly 20. Frame 212
includes frame members or uprights 214 that are circumferentially
spaced apart from each to define radial apertures 216. Frame 212
may be coupled to flush tube 82 below apertures 216 and frame
members 214 in order to provide an outlet for flush valve assembly
80. Illustratively, frame 212 is integrally coupled to flush tube
82, although alternative embodiments of frame 212 and flush tube 82
may be removably coupled to each other using conventional
fasteners.
As shown in FIGS. 7-9, flush tube 82 may be a cylindrical, or
tubular, structure. Flush tube 82 is fluidly coupled to inlet 68 of
bowl 60. An outer surface of flush tube 82 may include external
threads 83 in order to receive nut 122 when coupling base 30 to
tank 70. Flush tube 82 may include support members 218 (FIG. 8)
extending inwardly to define a channel 220 for a guide rod 90 of
flapper 84. Additionally, flush tube 82 may be fluidly coupled to
overflow assembly 150.
As shown in FIG. 11, flapper 84 may include a channel 92 that
receives a seal 94. Flapper 84 is configured for axial movement
within frame 212 and flush tube 82. Seal 94 also may move with
flapper 84. Additionally, guide rod 90 facilitates the axial
movement of flapper 84 and seal 94. Guide rod 90 is positioned
within channel 220 of flush tube 82 in order to properly position
flapper 84 within frame 212 during axial movement (FIG. 8).
With particular reference to FIG. 11, when flush valve assembly 80
is closed, flapper 84 engages a shoulder 222 of frame 212. As such,
when flush valve assembly 80 is in the closed position, seal 94 and
flapper 84 prevent water from flowing through flush tube 82 and
into bowl 60. In contrast, when flush valve assembly 80 is in an
open position, as shown in FIGS. 12-15, chain 208 axially pulls
flapper 84 and seal 94 away from shoulder 222. More particularly,
flapper 84 is held above shoulder 222 such that water may enter
flush tube 82 during a flush cycle.
Referring further to FIG. 9, overflow assembly 150 includes
overflow tube 152 and tank fill sensor 154 coupled thereto.
Overflow tube 152 is a cylindrical tube that is open at an upper
end 156 and a lower end 158 thereof. Upper end 156 of overflow tube
152 is in fluid communication with bowl refill tube 149 and
illustratively has a larger diameter than bowl refill tube 149 such
that bowl refill tube 149 is concentrically received within
overflow tube 152. Furthermore, lower end 158 of overflow tube 152
is in fluid communication with flush tube 82 of flush valve
assembly 80. As such, water entering upper end 156 of overflow tube
152 flows down overflow tube 152, through lower end 158 and flush
tube 82, and into bowl 60. More particularly, if the water level in
tank 70 rises above upper end 156 of overflow tube 152, the water
above upper end 156 is directed into bowl 60 through overflow tube
152 and flush tube 82. As such, the height or position of upper end
156 of overflow tube 152 may prevent the water in tank 70 from
overflowing. Furthermore, it may be appreciated that lower end 158
is positioned below flapper 84, which allows water to flow from
overflow tube 152, into flush tube 82, and into bowl 60 when flush
valve assembly 80 is in both the open position and the closed
position.
Tank fill sensor 154 may be coupled to the outer surface of
overflow tube 152. Additionally, tank fill sensor 154 is in
electronic communication with controller 230 (FIG. 19). For
example, overflow sensor may be a piezoelectric element, an
infrared sensor, a radio frequency ("RF") device, a mechanical
latching switch, or a capacitive sensor, in wired or wireless
communication with controller 230. Tank fill sensor 154 may detect
an overflow condition, such as when a water level in tank 70 rises
above a predetermined water level. As such, tank fill sensor 154,
controller 230, and fill valve assembly 130 operate together to
prevent water from overflowing from tank 70, as further detailed
herein.
In use, toilet 10 may be operated by initiating the flush cycle, as
shown in FIGS. 11-18. More particularly, and referring to FIG. 11,
when a user desires to flush toilet 10, the user activates flush
sensor 234 (FIG. 19). For example, a user's hand may be placed in
proximity to (e.g., placed in front of) indicator 88 in order to
trigger the flush cycle. Flush actuation sensor 234 receives the
user input and sends a signal to controller 230, which may initiate
operation of flush valve assembly 80 and fill valve assembly 130.
Before initiating the flush cycle, controller 230 (FIG. 19)
receives signals from bowl overflow sensor 226 to determine if the
water level in bowl 60 is below the predetermined critical water
level. If the water level in bowl 60 is below the critical level,
then controller 230 will initiate the flush cycle. Conversely, if
bowl overflow sensor 226 signals to controller 230 that the water
level in bowl 60 is above the critical level, controller 230 will
not initiate a flush cycle.
In response to the signal from flush actuation sensor 234,
controller 230 sends a signal to fill valve assembly 130, which
initiates the flush cycle (FIG. 19). In particular, when valve
assembly 140 is actuated, armature 176 of valve assembly 140 moves
toward pole 174 to close gap 179 and unseal pilot hole 166, thereby
allowing a portion of diaphragm 162 to flex away from valve seat
160 (FIG. 18B). Water from supply tube 22 may flow between valve
seat 160 and diaphragm 162 to provide fluid communication between
inlet 132 and bowl refill outlet 134, tank refill outlet 136, and
flush actuator outlet 138.
Water flows from supply tube 22, through inlet 132, into valve
assembly 140, through flush actuator outlet 138, and into flush
actuator assembly 86. The incoming water pressurizes flush actuator
assembly 86 and, more particularly, depresses diaphragm 190,
thereby causing piston 184 to move axially downward in cylinder
200, as shown in FIG. 12. The water pressure is sufficient to
overcome the bias in spring 182 in order to lower piston 184 and
compress spring 182. For example, the pressure in flush actuator
assembly 86 may be 10-15 psi in order to overcome the bias of
spring 182 and initiate movement of diaphragm 190.
The downward movement of piston 184 causes piston rod 186 to also
move downwardly. At the initiation of the flush cycle, piston rod
186 and piston lever 102 are spaced apart from lever arm 100 (FIG.
11). However, as piston rod 186 is pushed further downward by the
water pressure applied to diaphragm 190 and piston 184, piston
lever 102 contacts first end 115 of lever arm 100 (FIG. 12). In
response, lever arm 100 pivots upwardly in housing 210. More
particularly, second end 117 of lever arm 100 moves upwardly,
thereby pulling chain 208 upwardly in tension.
Referring to FIGS. 12 and 13, the upward movement of chain 208
causes flush valve assembly 80 to open. Illustratively, flush valve
assembly 80 opens when flapper 84 moves away from flush tube 82 in
response to the upward movement of chain 208 and second end 117 of
lever arm 100. As flush valve assembly 80 opens, water from tank 70
flows through apertures 216 and into flush tube 82 in order to
enter bowl 60 via inlet 68. As such, substantially all of the water
in tank 70 may flow into bowl 60 when flush valve assembly 80 is
open. The sudden increase in water in bowl 60 creates a siphon
effect in trapway 24, whereby fluid and other contents of bowl 60
are pulled or suctioned out of bowl 60 and into trapway 24 and
drain 26.
As shown in FIGS. 14 and 15, at full travel, first end 115 of lever
arm 100 slips past piston lever 102. As such, piston lever 102 is
clear of lever arm 100 and may no longer be in contact therewith.
Second end 117 of lever arm 100 pivots downwardly to its original
position due to its weight and the weight of chain 208 (FIG. 16).
The downward movement of lever arm 100 simultaneously releases the
tension on chain 208, however, flapper 84 may remain in an open
position while water is in tank 70. More particularly, due to
buoyancy, flapper 84 may initially remain open when water is in
tank 70. However, as the water level in tank 70 decreases, flapper
84 may close due to a loss of buoyancy and a decrease in the
velocity of the water flowing from tank 70 into bowl 60. For
example, flapper 84 may include a plurality of holes (not shown)
which allow water to flow into flapper 84, thereby decreasing its
buoyancy. As such, flapper 84 may move downwardly through the water
in tank 70 and close while water is still in tank 70. The holes in
flapper 84 may be arranged according to predetermined conditions of
the flush cycle, such as flush volume (e.g., 1.28 gallons/flush)
and the desired duration of the flush cycle. Valve assembly 80 is
closed when flapper 84 is seated on shoulder 222 of frame 212 in
order to retain water in tank 70.
After flush valve assembly 80 closes, tank 70 and bowl 60 may be
refilled with water. In order to refill tank 70 and bowl 60 after
toilet 10 has been flushed, valve assembly 140 remains in the open
position such that bowl refill outlet 134, tank refill outlet 136,
and flush actuator outlet 138 remain open. Water from supply tube
22 flows through bowl refill outlet 134 and into bowl refill tube
149 in order to flow through overflow tube 152 and into bowl 60 via
flush tube 82. As detailed herein, lower end 158 of overflow tube
152 is fluidly coupled to flush tube 82 below flapper 84 such that
water from overflow tube 152 may flow into bowl 60 when flush valve
assembly 80 is closed.
While bowl 60 is being refilled, water from supply tube 22 also may
flow through tank refill outlet 136 and into tank refill tube 139
in order to replenish the water in tank 70. With flush valve
assembly 80 in the closed position, the water flowing from tank
refill tube 139 remains in tank 70. Tank refill sensor 154 may be
used to indicate to controller 230 when tank 70 has been
sufficiently replenished with water. Fill valve assembly 130 may be
calibrated such that bowl 60 and tank 70 are sufficiently
replenished with water at approximately the same time. Any excess
water in tank 70 may flow into overflow tube 152, through flush
tube 82, and into bowl 60 in order to spill over into trapway 24.
However, under normal or correct operation of tank refill sensor
154, there is no excess water in tank 70.
Flush actuator assembly 86 may remain pressurized when inlet 132
and outlets 134, 136, 138 are open, such that diaphragm 190, piston
184, and piston rod 186 remain depressed. In order to relieve the
pressure in flush actuator assembly 86, valve assembly 140 moves to
the closed position. With particular reference to FIG. 18A, a
magnetic force is no longer generated and the bias of spring 178
pushes armature 176 away from pole 174. As such, pilot hole 166 is
sealed, thereby pressurizing diaphragm 162 and preventing water
flow between valve seat 160 and diaphragm 162. More particularly,
the force behind diaphragm 162 overcomes the force at the front of
diaphragm 162 (i.e., the force created by the water at inlet 132)
such that diaphragm 162 does not flex in response thereto.
With inlet 132 sealed, the water depressing diaphragm 190 may flow
upward through flush actuator outlet 138 in order to be released
through outlets 134, 136 while tank 70 and bowl 60 are being
refilled. Alternatively, fill valve assembly 130 may include a
separate bleed hole (not shown) to release the water in flush
actuator assembly 86. By reducing the water pressure in flush
actuator assembly 86, diaphragm 190, piston 184, spring 182, and
piston rod 184 move upwardly due to the bias of spring 182, as
shown in FIG. 17. This upward movement allows piston lever 102 to
rotate over first end 115 of lever arm 100 and return to its
original position (FIG. 11).
Piston lever 102 may not be in contact with lever arm 100 at the
end of the flush cycle and, as such, it may be necessary for a user
to wait until the pressure in flush actuator assembly 86 has been
relieved before another flush cycle may be initiated. Alternative
embodiments of controller 230 may be configured to send a signal to
valve assembly 140 in order to initiate an additional flush cycle
before tank 70 and bowl 60 have been fully refilled.
Alternative embodiments of indicator 88 may include a lens in order
to be illuminated with a light source (e.g., a light-emitting diode
("LED")) or other device. As such, at least a portion of indicator
88 may be illuminated according to certain applications of the
system. For example, controller 230 may illuminate indicator 88
during certain hours, such as at night, or when the lavatory is
dark. For example, indicator 88 may include a photo sensor to
detect the absence of light. Additionally, controller 230 may
illuminate indicator 88 when it is time to change battery 232 (FIG.
19). Alternatively, indicator 88 may be illuminated with a red
color to indicate that battery 232 should be changed, and a green
color to indicate that battery 232 is sufficiently supplying
power.
Referring to FIGS. 20-22, an alternative illustrative embodiment
toilet 1010 is shown including a tank 1020, a base 1032, a bowl
1034, an inlet tube, illustratively a water supply tube 1036, an
outlet tube, illustratively a trapway 1038, a fill valve assembly
1040, a flush valve assembly 1100, and an overflow assembly 1190.
Illustratively, toilet 1010 is a tank-type, gravity-fed toilet.
Additionally, illustrative toilet 1010 does not include an external
handle for flushing toilet 1010, but rather, toilet 1010 is an
automatic and hands-free toilet using an electronic sensor to
initiate a flush cycle. Alternatively, other embodiments of toilet
1010 may be contemplated. In operation, water from tank 1020 flows
into bowl 1034 in order to flush toilet 1010 and remove the
contents of bowl 1034 through trapway 1038. A sealing member (not
shown) may be provided between trapway 1038 and a floor (not shown)
to prevent water leakage onto the floor.
Tank 1020 includes a lid 1022, a bottom surface 1029 generally
opposite lid 1022, a front surface 1024, a rear surface 1026
generally opposing front surface 1024, a first side 1028
intermediate front surface 1024 and rear surface 1026, and a second
side 1030 generally opposing first side 1028 and positioned
intermediate front surface 1024 and rear surface 1026. Tank 1020
may be comprised of a ceramic, metallic, or polymeric material, for
example porcelain, stainless steel, or plastic composite materials.
Rear surface 1026 includes an external recessed channel 1027 which
guides supply tube 1036 into tank 1020 above the water level in
tank 1020 and allows tank 1020 to be positioned closer to the wall
because supply tube 1036 does not extend outwardly from tank 1020.
As shown in FIG. 24, supply tube 1036 is in fluid communication
with flush valve assembly 1100 and overflow assembly 1190 through
fill valve assembly 1040. In particular, supply tube 1036 is
fluidly coupled to a water supply (not shown) in order to flow
water into fill valve assembly 1040, as is further detailed
herein.
Base 1032 of toilet 1010 is a pedestal-type configured to rest atop
the floor. Brackets or other mounting assemblies (not shown) may be
used to couple base 1032 to the floor and/or to tank 1020, as
disclosed in U.S. Provisional Patent Application No. 61/610,205,
filed on Mar. 13, 2012, the complete disclosure of which is
expressly incorporated by reference herein. Base 1032 supports tank
1020 and bowl 1034 above the floor. In the illustrative embodiment,
base 1032 integrally supports trapway 1038 and is a
concealed-trapway type. More particularly, trapway 1038 is hidden
from view by sidewalls 1032a, 1032b of base 1032 (FIG. 21). Base
1032 may be comprised of a ceramic, metallic, or polymeric
material. For example, base 1032 may be comprised of porcelain,
stainless steel, or plastic composite materials. Referring to FIG.
21, trapway 1038 is illustratively curved and is coupled to bowl
1034 and a drain tube (not shown). The drain tube connects trapway
1038 to a main sewer line (not shown) to carry away the contents of
bowl 1034.
To limit contact between the water in toilet 1010 and metallic
components, supply tube 1036 and/or trapway 1038 may be formed of a
non-metallic material, such as a polymeric material (e.g., a
cross-linkable polymer) and/or a ceramic material. Alternatively,
supply tube 1036 and/or trapway 1038 may be lined with a
non-metallic material. As such, supply tube 1036 and trapway 1038
are electrically non-conductive.
As shown in FIGS. 22-28, a housing 1050 supports both a flush
actuator assembly 1108 and fill valve assembly 1040. Fill valve
assembly 1040 includes an inlet 1042, a refill outlet 1044, a flush
actuator outlet 1046 (FIG. 28), and an electrically-operable valve
assembly 1048 (FIG. 24). Referring to FIGS. 23 and 24, housing 1050
may include an upper portion 1052 and a lower portion 1054.
Illustratively, upper portion 1052 is integral with lower portion
1054, however, upper portion 1052 may be coupled to lower portion
1054 through a threaded or friction connection or with conventional
fasteners, as disclosed in U.S. Provisional Patent Application No.
61/610,205, filed on Mar. 13, 2012, the complete disclosure of
which is expressly incorporated by reference herein. Upper portion
1052 supports inlet 1042, outlets 1044, 1046, and
electrically-operable valve assembly 1048. Lower portion 1054 may
be coupled to flush valve assembly 1100 with fasteners 1102, such
as screws or bolts, and also may support flush actuator assembly
1108. Fill valve assembly 1040 may be comprised of a polymeric
material to limit contact between the water and metallic
components. Alternatively, fill valve assembly 1040 may be lined
with a non-metallic material. As such, fill valve assembly 1040 is
illustratively electrically non-conductive.
Inlet 1042 is fluidly coupled with supply tube 1036. More
particularly, inlet 1042 may include external threads 1056 that
threadedly couple with an internally-threaded nut 1058 to join
supply tube 1036 thereto. Rear surface 1026, first side 1028, or
second side 1030 of tank 1020 may include an internal support
member or bracket (not shown) to support the connection between
supply tube 1036 and inlet 1042. In particular, the connection
between supply tube 1036 and inlet 1042 may occur within tank
1020.
Electrically-operable valve assembly 1048 is positioned within
housing 1050 and is in fluid communication with inlet 1042, refill
outlet 1044, and flush actuator outlet 1046. Electrically-operable
valve assembly 1048 is threadedly coupled to upper portion 1052 of
housing 1050 through external threads 1084 and internal threads
1086 (FIG. 24). As such, electrically-operable valve assembly 1048
is integral with housing 1050 because a portion of
electrically-operable valve assembly 1048 forms the connection
point for coupling electrically-operable valve assembly 1048 with
upper portion 1052 of housing 1050.
Referring to FIGS. 24 and 28, electrically-operable valve assembly
1048 may be, for example, an electromechanical valve, and more
particularly, may be a solenoid valve of the latching-type.
Exemplary electrically-operable valve assembly 1048 may include a
filter 1070, slots 1080, a seal 1082, and a body portion 1060
supporting a valve seat 1061, a diaphragm 1062, a shaped portion
1064, illustratively a V-shaped groove, a pilot hole 1066, a seal
1068, a magnet 1072, a pole 1074, an armature 1076, and a spring
1078. As shown in FIG. 24, illustrative slots 1080 are rearward of
seal 1082 and filter 1070, and are forward of body portion 1060.
Electrically-operable valve assembly 1048 further includes
electrical wires 1088 extending from body portion 1060 to supply
power thereto.
Electrically-operable valve assembly 1048 is in electrical
communication with controller 1208 (FIG. 40). During operation of
toilet 1010, electrically-operable valve assembly 1048 receives
signals from controller 1208 to control the flow of water from
inlet 1042 to refill outlet 1044 and flush actuator outlet 1046, as
further detailed herein and in U.S. Provisional Patent Application
No. 61/610,205, filed on Mar. 13, 2012, the complete disclosure of
which is expressly incorporated by reference herein. For example,
electrically-operable valve assembly 1048 may be actuated by
controller 1208 to magnetically attract armature 1076 to pole 1074,
thereby allowing water from inlet 1042 to flow between valve seat
1061 and diaphragm 1062, and into outlets 1044 and 1046.
Electrically-operable valve assembly 1048 may be comprised of
polymeric or other electrically nonconductive materials.
As shown in FIG. 25A, when electrically-operable valve assembly
1048 is in the closed position, diaphragm 1062 engages valve seat
1061 due to the force behind diaphragm 1062. More particularly, the
force behind diaphragm 1062 is sufficient to overcome the force at
the front of diaphragm 1062. The resulting force behind diaphragm
1062 is due to water pressure at opposing front and rear surfaces
of diaphragm 1062 in combination with surface area differences
between the front and rear of diaphragm 1062. While the pressure at
the front and rear of diaphragm 1062 may be equalized (due to water
flow through shaped portions 1064), the greater surface at the rear
of diaphragm 1062 creates a greater force behind diaphragm 1062. As
such, diaphragm 1062 engages with valve seat 1061 such that water
flowing through filter 1070 from inlet 1042 (FIG. 28) may not pass
between diaphragm 1062 and valve seat 1061, thereby preventing
water from flowing through slots 1080 and into outlets 1044 and
1046.
The force behind diaphragm 1062 may be created when armature 1076
is spaced apart from pole 1074. A gap 1079 may be defined by the
space between armature 1076 and pole 1074 when valve assembly 1048
is in the closed position. In particular, spring 1078 biases
armature 1076 away from pole 1074 in order to position seal 1068
against pilot hole 1066. When pilot hole 1066 is sealed, a force is
maintained behind diaphragm 1062 to sealingly engage diaphragm 1062
with valve seat 1061.
However, as shown in FIG. 25B, when electrically-operable valve
assembly 1048 has been actuated by controller 1208, a short
electrical pulse is provided in order to move armature 1076 toward
pole 1074. When the electrical pulse is discontinued, armature 1076
will remain latched to, or otherwise in contact with, pole 1074 due
to a magnetic attraction to magnet 1072. This magnetic force is
sufficient to overcome the bias in spring 1078 to allow armature
1076 to move toward pole 1074 and close gap 1079. When armature
1076 contacts pole 1074, seal 1068 moves with armature 1076 and is
pulled away from pilot hole 1066, which creates a pressure and
force differential in valve assembly 1048. In particular, the
pressure behind diaphragm 1062 is reduced because pilot hole 1066
is no longer sealed. As such, diaphragm 1062 may flex, bend, or
otherwise move in response to the force from the water at inlet
1042. As such, water may flow through filter 1080 in the direction
of arrows 1083 and between diaphragm 1062 and valve seat 1061 in
order to flow through slots 1080 (FIG. 24) and into outlets 1044
and 1046.
When it is necessary to close electrically-operable valve assembly
1048, a short electrical pulse is provided in order to generate a
magnetic force opposite that of magnet 1072. The opposing magnetic
force unlatches armature 1076 from pole 1074 in order to move
armature 1076 toward seal 1068. Spring 1078 facilitates the
movement of armature 1076 toward seal 1068 because the electrical
pulse has a short duration, for example 25 milliseconds. Additional
details of the operation of electrically-operable valve assembly
1048 are disclosed in U.S. Provisional Patent Application No.
61/610,205, filed on Mar. 13, 2012, the complete disclosure of
which is expressly incorporated by reference herein.
Referring to FIG. 24, the illustrative embodiment of fill valve
assembly 1040 includes two outlets 1044 and 1046, however, any
number of outlets may be included to accommodate particular
applications of fill valve assembly 1040. Refill outlet 1044 may be
integrally formed with housing 1050 and extend therefrom.
Illustratively, refill outlet 1044 may generally extend from
housing 1050 and may be approximately perpendicular to inlet 1042.
Additionally, as shown in FIGS. 26 and 27, refill outlet 1044 may
be fluidly coupled to an outlet tube 1090, which illustratively is
coupled to a bowl refill tube 1092 and a tank refill tube 1094.
As shown in FIGS. 23 and 24, exemplary bowl refill tube 1092
includes first and second generally right-angle bends 1092a, 1092b
in order to extend away from outlet tube 1090 and toward an
overflow tube 1192 of overflow assembly 1190. Illustratively, bowl
refill tube 1092 extends around tank refill tube 1094 and over a
cylindrical housing 1162 of flush valve assembly 1100 in order to
couple with overflow tube 1192. Bowl refill tube 1092 may be
smaller in diameter than overflow tube 1192 such that it is may be
received therein. The illustrative embodiment of bowl refill tube
1092 may be received within a cap 1202 on overflow tube 1192, as
shown in FIG. 23.
As shown in FIG. 24, outlet tube 1090 also is fluidly coupled tank
refill tube 1094 which, illustratively, is positioned intermediate
refill outlet 1044 and bowl refill tube 1092. Tank refill tube 1094
extends downwardly from outlet tube 1090 and may be positioned near
bottom wall 1029 of tank 1020. As such, the position of tank refill
tube 1094 may prevent water splashing and/or a user from hearing
the water in tank refill tube 1094 contacting bottom wall 1029 of
tank 1020 when tank 1020 is being refilled.
Outlet tube 1090 includes an inlet 1090a fluidly coupled to refill
outlet 1044 of fill valve assembly 1040, a tank outlet 1090b
fluidly coupled to tank refill tube 1094, a bowl outlet 1090c
fluidly coupled to bowl refill tube 1092, and a plunger end 1090d
generally opposite inlet 1090a and including an opening 1090e.
Alternatively, bowl refill tube 1092 may be removed from fill valve
assembly 1040. Instead, overflow tube 1192 may be aligned with bowl
outlet 1090c such that water flowing from bowl outlet 1090c flows
into overflow tube 1192. At least two resilient arms 1093 are
positioned near inlet 1090a and are configured to extend into
refill outlet 1044 in order to secure outlet tube 1090 therein.
Additionally, a plurality of protrusions or stops 1095 and a
plurality of channels 1096 are positioned adjacent resilient arms
1093. Channels 1096 receive o-rings 1101 for sealing outlet tube
1090 to refill outlet 1044. Stops 1095 are configured to fit within
a plurality of recesses 1045 at refill outlet 1044 to limit the
distance that outlet tube 1090 extends within refill outlet
1044.
Referring to FIGS. 26 and 27, outlet tube 1090 is configured to
receive a plunger 1097 through inlet 1090a. Plunger 1097 has a body
portion 1097c extending between a rounded end 1097a and a generally
flat or planar end 1097b. A tip 1098 extends from flat end 1097b.
Body portion 1097c of plunger 1097 includes a plurality of ribs
1099 extending between rounded end 1097a and flat end 1097b. Ribs
1099 are spaced apart from each other and define channels 1091
therebetween. Ribs 1099 increase the strength and stability of
plunger 1097. Plunger 1097 is narrower at channels 1091 of body
portion 1097c relative to rounded end 1097a. As such, the
clearance, or flow path, between the inner diameter (id) of outlet
tube 1090 and body portion 1097c of plunger 1097 is greater than
the clearance, or flow path, between the inner diameter (id) of
outlet tube 1090 and the rounded end 1097a of plunger 1097.
In operation, when fill valve assembly 1040 is actuated, water
flows from supply tube 1036, through refill outlet 1044, and into
inlet 1090a of outlet tube 1090. Water flows past plunger 1097 and
exits outlet tube 1090 through tank and bowl outlets 1090b and
1090c to flow into tank refill tube 1094 and bowl refill tube 1092,
respectively. The water entering outlet tube 1090 pushes plunger
1097 toward plunger end 1090d of outlet tube 1090 such that tip
1098 extends through opening 1090e. As such, plunger 1097 is
generally positioned above bowl outlet 1090c and tank outlet 1090b.
As the water flows toward plunger 1097 and tank and bowl outlets
1090b and 1090c, the flow path for the water narrows because the
clearance between rounded end 1097a of plunger 1097 and the inner
diameter (id) of outlet tube 1090 is less than the inner diameter
(id) of outlet tube 1090. Therefore, as water flows into outlet
tube 1090, the water velocity increases because the flow path at
plunger 1097 is restricted relative to the flow path at inlet
1090a. Because the flow path in outlet tube 1090 is restricted, the
water pressure at inlet 1090a increases, as detailed further
herein. Channels 1091 provide a gradual transition for the water
velocity to decrease when transitioning from the restricted flow
path at rounded end 1097a to the unrestricted flow path in bowl and
tank refill tubes 1092 and 1094, which may decrease the amount of
noise produced by the restricted water flow.
If a vacuum occurs at inlet 1042 of fill valve assembly 1040,
plunger 1097 moves away from plunger end 1090d and toward inlet
1090a of outlet tube 1090 such that tip 1098 is spaced apart from
opening 1090e. As plunger 1097 moves away from opening 1090e,
plunger 1097 "breaks" any vacuum at inlet 1042, thereby preventing
water from flowing into electrically-operable valve assembly 1048
and supply tube 1036.
Illustratively, fill valve assembly 1040 is controlled by
controller 1208 (FIG. 40). More particularly, controller 1208
receives a signal from a bowl sensor 1210 coupled to bowl 1034
which determines if an overflow condition has occurred in bowl
1034. Bowl sensor 1210 is coupled to bowl 1034 with adhesive, for
example an adhesive tape 1212, or other similar materials, which
may eliminate the need for invasive fasteners, such as bolts or
screws, which would penetrate bowl 1034 and form a potential
leakage point. Illustratively, bowl sensor 1210 is integral with
adhesive tape 1212, which may be conductive. For example, bowl
sensor 1210 is in contact with bowl 1034 and an electrical
connection, such as a rivet or snap, coupled to bowl sensor 1210 to
tape 1212.
Bowl sensor 1210 is configured to detect an overflow condition,
such as when the water level in bowl 1034 rises above a
predetermined, critical level. In particular, bowl sensor 1210 may
prevent operation of fill valve assembly 1040 when an overflow
condition is detected. Therefore, bowl sensor 1210 also may prevent
operation of flush actuator assembly 1108 and flush valve assembly
1100 when an overflow condition is detected. Alternatively, when an
overflow condition is not signaled by bowl sensor 1210, controller
1208 (FIG. 40) may send a signal to electrically-operable valve
assembly 1048 to initiate a flush cycle, as further detailed
herein. Bowl sensor 1210 also may be configured to detect a water
leak in bowl 1034 and signal a leak condition to controller 1208.
Controller 1208, through an indicator 1110 on tank 1020, may signal
a user that bowl 1034 has a leak condition and/or an overflow
condition. Bowl sensor 1210 may be a piezoelectric element, an
infrared sensor, a radio frequency ("RF") device, a capacitive
sensor, a float device, an ultrasound device, or an electric field,
for example. Illustratively, bowl sensor 1210 is a capacitive
sensor.
Referring to FIGS. 23, 24, and 28, fill valve assembly 1040 is
fluidly coupled to flush actuator assembly 1108 through flush
actuator outlet 1046. Illustratively, flush actuator outlet 1046
may be a conduit extending from housing 1050 to flush valve
assembly 1100. Flush valve assembly 1100 includes a flush tube
1104, flush valve flapper 1106, flush actuator assembly 1108,
indicator 1110, and a flush actuation sensor 1112 (FIG. 40). Flush
actuation sensor 1112 cooperates with indicator 1110 (FIGS. 21 and
22) and controller 1208 (FIG. 40) to initiate a flush cycle.
Indicator 1110 may be coupled to tank 1020 and extend therefrom, as
shown in FIGS. 21 and 22. More particularly, indicator 1110 and
controller 1208 may be coupled to the same wall of tank 1020 such
that the wall is intermediate flush indicator 1110 and controller
1208. Illustratively, controller 1208 and indicator 1110 may be
supported by a waterproof housing or casing 1114 in tank 1020
(FIGS. 30-32). Casing 1114 may also house at least one battery 1116
(FIG. 31) in order to supply power to controller 1208.
Additionally, other electronic components may be housed within
casing 1114, for example, indicator 1110 may include additional
sensors electrically coupled to controller 1208.
Flush actuation sensor 1112 may be a piezoelectric element, an
infrared sensor, a radio frequency ("RF") device, a capacitive
sensor, a float device, an ultrasound device, or an electric field,
for example. Illustratively, flush actuation sensor 1112 is a
capacitive sensor. Flush actuation sensor 1112 is configured to
receive a user input and is in electronic communication with
controller 1208 (FIG. 40). In one illustrative embodiment, flush
actuation sensor 1112 may be a capacitive sensor, using touch or
hands-free proximity sensing. By incorporating capacitive sensing
into toilet 1010, a single microchip may be used to electrically
communicate with flush actuation sensor 1112, bowl sensor 1210, and
a tank sensor 1194 (FIG. 23). Additionally, capacitive sensing may
allow bowl sensor 1210 (FIG. 21) to sense through bowl 1034 without
adding holes to bowl 1034. Furthermore, as is known, capacitive
sensing provides for robust electrical communication and may be
less expensive than other sensing mechanisms.
As shown in FIG. 28 and further disclosed in U.S. Provisional
Patent Application No. 61/610,205, filed on Mar. 13, 2012, the
complete disclosure of which is expressly incorporated by reference
herein, flush actuator assembly 1108 may include a piston assembly
1120 coupled to a diaphragm 1122 within a cylinder 1124. Cylinder
1124 is defined by upper and lower portions 1052, 1054 of housing
1050. Because upper and lower portions 1052, 1054 are integral with
each other and fill valve assembly 1040, cylinder 1124 also is
integral with fill valve assembly 1040, including
electrically-operable valve assembly 1048, through housing 1050.
Lower portion 1054 of housing 1050 illustratively includes a
channel 1126 which receives a lip 1128 of diaphragm 1122. Lip 1128
of diaphragm 1122 is positioned within channel 1126 between upper
and lower portions 1052, 1054 of housing 1050. Upper portion 1052
may include protrusions 1130 which depress into lip 1128 of
diaphragm 1122 in order to further secure diaphragm 1122 to
cylinder 1124. A sealing end 1132 of diaphragm 1122 may be coupled
to piston assembly 1120 with a screw 1134. As such, sealing end
1132 of diaphragm 1122 may form a seal between piston assembly 1120
and cylinder 1124. Illustratively, diaphragm 1122 is a rolling
diaphragm and may move with piston assembly 1120, as further
detailed herein. Diaphragm 1122 may be comprised of a flexible
elastomeric material. During operation, diaphragm 1122 provides a
long stroke with minimal friction, which reduces the minimum amount
of friction needed to operate piston assembly 1120. Additionally,
by decreasing the amount of friction necessary to operate piston
assembly 1120, the stiffness of spring 1136 may be reduced. Because
piston assembly 1120 may operate at a reduced pressure, toilet 1010
will continue to operate even in situations when the water pressure
decreases (e.g., a well water supply or water is simultaneously
running to other devices within a building).
As shown in FIG. 28, piston assembly 1120 illustratively includes a
spring 1136, piston 1138, a piston rod 1140, and a retainer plate
1142 coupled to the top of piston 1138 with screw 1134 or other
fastener. Piston 1138 is coupled to sealing end 1132 of diaphragm
1122 via retainer plate 1142 and screw 1134. As such, retainer
plate 1142 also fluidly seals piston assembly 1120 from upper
portion 1052 of housing 1050. In operation, water pressure may be
used to engage flush actuator assembly 1108 and move piston
assembly 1120. Additionally, a lower surface 1144 of cylinder 1124
may include apertures 1146 (FIG. 33) for releasing or exhausting
air from cylinder 1124 during operation of flush actuator assembly
1108.
Illustrative piston 1138 may have a generally round shape that is
substantially hollow (e.g., inverted cup shape). At least a portion
of spring 1136 and piston rod 1140 are illustratively positioned
within piston 1138. Piston rod 1140 may be coupled to piston 1138
via screw 1134. Piston rod 1140 extends downwardly from piston 1138
and through an aperture 1148 in cylinder 1124 to extend below
cylinder 1124. As shown in FIG. 28, piston rod 1140 may be
selectively coupled to a lever arm 1150 through a piston lever
1152. Piston lever 1152 may be pivotably coupled to piston rod 1140
and is configured to selectively engage lever arm 1150.
Referring to FIG. 28, lever arm 1150 includes a first end 1154 and
an opposing second end 1156. First end 1154 is adjacent piston
lever 1152 and may be in contact with piston lever 1152 during a
flush cycle of toilet 1010. A pivot member 1155 may be coupled to
first end 1154 of lever arm 1150 in order to pivotally contact
piston lever 1152, as is detailed further herein. Lever arm 1150
and piston lever 1152 may pivot relative to a bracket 1153 coupled
to lower portion 1054 of housing 1050. An opening 1157 in bracket
1153 allows lever arm 1150 to pivot within housing 1162 of flush
valve assembly 1100.
As shown in FIG. 33, second end 1156 of lever arm 1150 is
illustratively coupled to flapper 1106 through a channel 1158.
Channel 1158 is supported on a post 1160 of flush valve assembly
1100 and is positioned within housing 1162. Channel 1158 cooperates
with lever arm 1150 to raise and lower flapper 1106 with the
movement of lever arm 1150 during the flush cycle, as is detailed
further herein. The illustrative embodiment of flush valve assembly
1100 is chainless because flapper 1106 is coupled to post 1160
rather than a chain. By using a rigid rod, shaft, or other similar
structure, such as post 1160, it is more likely that flush valve
assembly 1100 will operate properly when opening and closing
flapper 1106. More particularly, if post 1160 is substituted with a
chain, it is more likely that the chain may kink or otherwise fold
or overlap, which may prevent the chain from fully extending. As
such, a chain may not allow flapper 1106 to fully close and water
may continuously flow from tank 1020 to bowl 1034. However, by
using post 1160, rather than a chain, flush valve assembly 1100
operates properly to fully open and close flapper 1106.
Referring to FIGS. 23, 24, and 29, flapper 1106 of flush valve
assembly 1100 is positioned within a frame 1164 coupled to housing
1162 (FIG. 33). More particularly, housing 1162 is illustratively
coupled to the top of frame 1164. Housing includes a plurality of
slots 1166 which allows water to pass into and out of housing 1162.
Housing 1162 may be configured for rotation relative to frame 1164
in order to accommodate various sizes and spatial arrangements of
tank 1020 and supply tube 1036. Frame 1164 includes frame members
or uprights 1168 that are circumferentially spaced apart from each
to define radial apertures 1170. Frame 1164 may be coupled to flush
tube 1104 below apertures 1170 and frame members 1164 in order to
provide an outlet for flush valve assembly 1100. Illustratively,
frame 1164 is integrally coupled to flush tube 1104, although
alternative embodiments of frame 1164 and flush tube 1104 may be
removably coupled to each other using conventional fasteners.
As shown in FIGS. 22-24, flush tube 1104 may be a cylindrical, or
tubular, structure. Flush tube 1104 is fluidly coupled to bowl
1034, as shown in FIG. 21. An outer surface of flush tube 1104 may
include external threads 1172 in order to receive nut 1174 for
coupling flush valve 1104 to tank 1020. Flush tube 1104 may include
support members 1176 (FIG. 29) extending inwardly to define a guide
1178 for post 1160 of flush valve assembly 1100. Additionally,
flush tube 1104 may be fluidly coupled to overflow assembly 1190.
Illustrative post 1160, shown in FIG. 24, includes an upper end
1160a and a lower end 1160b. Post 1160 extends through flapper 1106
such that upper end 1160a extends above flapper 1106 and through an
aperture 1163 of housing 1162, and lower end 1106b extends below
flapper 1106 and into guide 1178. Post 1160 may include ribs 1180
which may increase the strength and stability of post 1160.
As shown in FIG. 29, flapper 1106 may include a channel 1182 that
receives a seal 1184. Flapper 1106 is configured for axial movement
within frame 1164 and flush tube 1104, and seal 1184 also may move
with flapper 1106. Additionally, post 1160 facilitates the axial
movement of flapper 1106 and seal 1184. Post 1160 is positioned
within guide 1178 of flush tube 1104 in order to properly position
flapper 1106 within frame 1164 during axial movement. Therefore,
post 1160 ensures that flapper 1106 is aligned on frame 1164 in
order to properly seal flush valve assembly 1100. The alignment of
flapper 1106 on frame 1164 provides repeatable operation and
performance of toilet 1010 because the amount of water is dispersed
from tank 1020 to bowl 1034 is generally consistent for every flush
cycle.
With reference to FIG. 29, when flush valve assembly 1100 is
closed, flapper 1106 engages a shoulder 1186 of frame 1164.
Shoulder 1186 extends in a generally vertical direction relative to
frame 1164. As such, when flush valve assembly 1100 is in the
closed position, seal 1184 and flapper 1106 prevent water from
flowing through flush tube 1104 and into bowl 1034. In contrast,
when flush valve assembly 1100 is in an open position, as shown in
FIGS. 34-37, post 1160 cooperates with lever arm 1150 to axially
pull flapper 1106 and seal 1184 upwards and away from shoulder
1186. More particularly, flapper 1106 is held above shoulder 1186
such that water may enter flush tube 1104 during a flush cycle.
Referring further to FIGS. 23 and 24, overflow assembly 1190
includes overflow tube 1192 and tank sensor 1194 coupled thereto.
Overflow tube 1192 is a cylindrical tube that is open at an upper
end 1196 and a lower end 1198 thereof. Upper end 1196 of overflow
tube 1192 is in fluid communication with bowl refill tube 1092 and
illustratively has a larger diameter than bowl refill tube 1092. As
shown in FIG. 23, bowl refill tube 1092 is received within a
bracket 1200 on cap 1202 at upper end 1196 of overflow tube 1192.
As such, bowl refill tube 1092 does not extend within overflow tube
1192 but is fluidly coupled thereto, such that water flowing from
bowl refill tube 1092 flows into overflow tube 1192. Alternatively,
bowl refill tube 1092 may extend within overflow tube 1192.
Lower end 1158 of overflow tube 1192 is in fluid communication with
flush tube 1104 of flush valve assembly 1100 through a bracket
1204. Bracket 1204 may be integrally formed with frame 1164 of
flush valve assembly 1100 or may be coupled thereto with
conventional fasteners. As such, water entering upper end 1196 of
overflow tube 1192 flows down overflow tube 1192, through lower end
1198 and flush tube 1104, and into bowl 1034. More particularly, if
the water level in tank 1020 rises above upper end 1196 of overflow
tube 1192, the water above upper end 1196 is directed into bowl
1034 through overflow tube 1192 and flush tube 1104. As such, the
height or position of upper end 1196 of overflow tube 1192 may
prevent the water in tank 1020 from overflowing. Furthermore, it
may be appreciated that lower end 1198 is positioned below flapper
1106, which allows water to flow from overflow tube 1192, into
flush tube 1104, and into bowl 1034 when flush valve assembly 1100
is in both the open position and the closed position.
Tank sensor 1194 may be coupled to the outer surface of overflow
tube 1192. More particularly, tank sensor 1194 is coupled to, or
integrally formed with, a clip 1206 positioned generally around
overflow tube 1192 near upper end 1196 thereof. Illustratively, as
shown in FIG. 23, clip 1206 and tank sensor 1194 are positioned
below cap 1202. Exemplary clip 1206 may be a metal ring crimped
onto overflow tube 1192. The position of clip 1206 and tank sensor
1194 may be adjustable along the length of overflow tube 1192 in
order to adjust the water level in tank 1020. Tank sensor 1194 is
in electronic communication with controller 1208 (FIG. 40). Tank
sensor 1194 may be a piezoelectric element, an infrared sensor, a
radio frequency ("RF") device, a capacitive sensor, a float device,
an ultrasound device, or an electric field in wired or wireless
communication with controller 1208, for example. Illustratively,
tank sensor 1194 is a capacitive sensor. A second tank sensor (not
shown) may be positioned in tank 1020 and configured to detect an
overflow condition, such as when a water level in tank 1020 rises
above a predetermined water level.
An alternative tank sensor 1194' may be supported by casing 1114 on
tank 1020. Referring to FIGS. 30-32, casing 1114 includes a first
portion 1220 and a second portion 1222. First portion 1220 may be
integrally formed with second portion 1222, or may be coupled
thereto with conventional fasteners. Second portion 1222 includes a
battery bracket 1252 for supporting batteries 1116 therein. A lid
1250 is removably coupled to second portion 1222 and seals second
portion 1222 from the water in tank 1020.
First portion 1220 supports indicator 1110, a cover member 1224, a
bracket 1226, an o-ring 1228, a lid 1230, a circuit board 1232, and
alternative embodiment tank sensor 1194', illustratively a metallic
bolt 1234 and an adjustment member 1240. Lid 1230 is removably
coupled to first portion 1220 via coupling members 1244, 1246 to
seal first portion 1220 from the water in tank 1020. Indicator 1110
is supported by bracket 1226 on first portion 1220. Illustratively,
bracket 1226 defines a square in cross-section and includes a
square opening 1258 for receiving a threaded portion 1254 of
indicator 1110. O-ring 1228 may be retained on threaded portion
1254 to seal opening 1258 of bracket 1226 when threaded portion
1254 is threadedly coupled with a threaded portion 1256 of first
portion 1220 of casing 1114 (FIG. 32).
Cover member 1224 is illustratively positioned outwardly from
bracket 1226 and, as shown in FIG. 22, also is positioned outward
from tank 1020. As such, indicator 1110 extends between cover
member 1224 and bracket 1226. In particular, cover member includes
an opening 1260 through which a portion of indicator 1110 may
extend. In this way, indicator 1110 and cover member 1224 are
externally visible on tank 1020 such that a user may know to
actuate flush actuation sensor 1112 through indicator 1110.
First portion 1220 further supports circuit board 1232 therein.
Circuit board 1232 is coupled to a support member 1248 within first
portion 1220 and includes various electrical components and
connections, such as a metallic base member 1236. Base member 1236
is coupled to circuit board 1232 through conventional means and
includes an aperture 1238 for receiving metallic bolt 1234
therethrough. More particularly, metallic bolt 1234 extends through
an aperture 1242 in lid 1230, through aperture 1238 in base member
1236, and through an aperture 1262 on the bottom surface of first
portion 1220 in order to extend into tank 1020. Similarly,
adjustment member 1240 partially extends through aperture 1242 in
lid 1230 and threadedly couples with bolt 1234 above base member
1236. A head portion 1264 of adjustment member 1240 is supported
above lid 1230.
When bolt 1234 is supported on base member 1236, bolt 1234 may be
electrically coupled to circuit board 1232 because bolt 1234 and
base member 1234 are both metallic and, therefore, may transmit an
electrical connection to circuit board 1232. Preferably, bolt 1234
is a capacitive sensor. As such, if water in tank 1020 contacts
bolt 1234, controller 1208 detects the increase in capacitance and
signals fill valve assembly 1040 to stop the flow of water into
tank 1020. As such, bolt 1234 and base member 1236 define
alternative tank sensor 1194' and may be used to signal to
controller 1208 that no additional water should be added to tank
1020. Controller 1208 may be supported on circuit board 1232, or
may be in electrical communication therewith, and receives the
electrical signal indicating that water in tank 1020 is at the
level of bolt 1234. Controller 1208 may then close fill valve
assembly 1040 to prevent additional water flowing into tank 1020.
Using adjustment member 1240, a user may rotate head portion 1264
of adjustment member 1240 in order to adjust the length of bolt
1234 extending from aperture 1262 and into tank 1020. Therefore,
the predetermined water level in tank 1020 may be adjusted. For
example, if a user wants to lower the predetermined water level in
tank 1020, the user may rotate head portion 1264 in a first
direction to move bolt 1234 away from head portion 1264 of
adjustment 1240 and further into tank 1020. Conversely, if a user
desires to raise the predetermined water level in tank 1020, the
user may, for example, rotate head portion 1264 in a second
direction to move bolt 1234 towards head portion 1264 and further
into first portion 1220 such that less of bolt 1234 extends into
tank 1020.
Both tank sensor 1194 and 1194' may be configured to cooperate with
controller 1208 to indicate a water leak in tank 1020. For example,
if the water level in tank 1020 no longer contacts tank sensor 1194
or 1194', controller 1208 may determine if a flush cycle was
initiated. If a flush cycle was not initiated, controller 1208 may
then indicate to a user, through indicator 1110, that tank 1020 has
a water leak (i.e., that the water level in tank 1020 is decreasing
between flush cycles).
In use, toilet 1010 may be operated by initiating the flush cycle,
as shown in FIGS. 33-39. More particularly, and referring to FIG.
33, when a user desires to flush toilet 1010, the user activates
flush actuation sensor 1112 (FIG. 40). For example, a user's hand
may be placed in proximity to (e.g., placed in front of) indicator
1110 in order to trigger the flush cycle. As such, toilet 1010 is
an automatic and hands-free flush toilet because a user normally
initiates a flush cycle through flush actuation sensor 1112, rather
than by depressing a manual handle or button on toilet 1010. Flush
actuation sensor 1112 receives the user input and sends a signal to
controller 1208 to initiate operation of flush valve assembly 1100
and fill valve assembly 1040. Before initiating the flush cycle,
controller 1208 (FIG. 40) receives signals from bowl sensor 1210 to
determine if the water level in bowl 1034 is above the
predetermined critical water level. If the water level in bowl 1034
is at or below the critical level, then controller 1208 will
initiate the flush cycle. Conversely, if bowl sensor 1210 signals
to controller 1208 that the water level in bowl 1034 is above the
critical level, controller 1208 will not actuate fill valve
assembly 1040 to initiate a flush cycle. In particular, when an
overflow condition is detected, water does not flow from inlet 1042
of fill valve assembly 1040 to outlets 1044, 1046. As such, water
does not flow into or from tank 1020 during an overflow condition.
Illustratively, water does not flow from inlet 1042 to flush
actuator outlet 1046 and, therefore, flush actuator assembly 1108
does not lift flapper 1106, which prevents water in tank 1020 from
flowing into bowl 1034. Additionally, water does not flow from
inlet 1042 to refill outlet 1044 and, therefore water does not flow
into tank 1020 through tank refill tube 1094 or into bowl 1034
through bowl refill tube 1092.
However, it may be appreciated that exemplary toilet 1010 is
configured to allow a user to flush toilet 1010 once after an
overflow condition has been detected. In particular, the user may
remove lid 1022 of toilet 1010 and manually pull post 1160 upwardly
through aperture 1163 of housing 1162 in order to manually lift
flapper 1106 and open flush valve assembly 1100. The water in tank
1020 will flow through flush valve assembly 1100, into bowl 1034,
and through trapway 1038 to flush toilet 1010. However, because an
overflow condition has been signaled to controller 1208, controller
1208 does not actuate fill valve assembly 1040 and, therefore, tank
1020 and bowl 1034 are not refilled. As such, a user is prevented
from manually flushing toilet 1010 more than once when an overflow
condition is detected because no water remains in tank 1020 for
another flush cycle.
Alternatively, toilet 1010 may include an external button, lever,
or other mechanical user interface device coupled to post 1160,
which would allow a user to manually flush toilet 1010 without
removing lid 1022. For example, the user may push, rotate, or
otherwise move a device externally coupled to toilet 1010 which
would raise post 1160, thereby opening flapper 1106, to allow water
to enter bowl 1034 without actuating controller 1208 or fill valve
assembly 1040. As such, post 1160 allows a user to override
controller 1208, and also allows a user to operate toilet 1010 one
time when battery 1116 needs to be replaced or the electrical
sensors and/or controller 1208 malfunction.
When an overflow condition is not detected, controller 1208 sends a
signal to fill valve assembly 1040 in response to the signal from
flush actuation sensor 1112, to initiate the flush cycle. In
particular, when electrically-operable valve assembly 1048 is
actuated, armature 1076 moves toward pole 1074 to close gap 1079
and unseal pilot hole 1066, thereby allowing a portion of diaphragm
1062 to flex away from valve seat 1061 (FIG. 25B). Water from
supply tube 1036 may flow between valve seat 1061 and diaphragm
1062 to provide fluid communication between inlet 1042 and refill
outlet 1044 and flush actuator outlet 1046.
Water flows from supply tube 1036, through inlet 1042, into
electrically-operable valve assembly 1048, through flush actuator
outlet 1046, and into flush actuator assembly 1108. Water also
simultaneously flows through refill outlet 1044 and into outlet
tube 1090. The incoming water pressurizes flush actuator assembly
1108 due, in part, to the flow restriction in outlet tube 1090
caused by plunger 1097. By pressurizing flush actuator assembly
1108, diaphragm 1122 is depressed, thereby causing diaphragm 1122
and piston 1138 to move axially downward in cylinder 1124, as shown
in FIGS. 34-36. The water pressure is sufficient to overcome the
bias in spring 1136 and the force caused by the weight of flapper
1106 and the water above flapper 1106 in order to lower piston 1138
and compress spring 1136. For example, the pressure in flush
actuator assembly 1108 may be 10-15 psi in order to overcome the
bias of spring 1136 and initiate movement of diaphragm 1122.
The downward movement of piston 1138 causes piston rod 1140 to also
move downwardly. At the initiation of the flush cycle, piston rod
1140 and piston lever 1152 are spaced apart from lever arm 1150
(FIG. 33). However, as piston rod 1140 is pushed further downward
by the water pressure applied to diaphragm 1122 and piston 1138,
piston lever 1152 contacts first end 1154 of lever arm 1150 (FIG.
34). In response, lever arm 1150 pivots upwardly in housing 1162.
More particularly, second end 1156 of lever arm 1150 moves upwardly
within channel 1158 of post 1160 until contacting an upper surface
1159 of channel 1158. When lever arm 1150 contacts upper surface
1159 of channel 1158, post 1160 moves upwardly with lever arm 1150.
As such, flapper 1106 moves upwardly as well.
Referring to FIGS. 34 and 35, the upward movement of post 1160 and
flapper 1106 causes flush valve assembly 1100 to open. As flush
valve assembly 1100 opens, water from tank 1020 flows through
apertures 1170 and into flush tube 1104 in order to enter bowl
1034. Substantially all of the water in tank 1020 may flow into
bowl 1034 when flush valve assembly 1100 is open. The sudden
increase in water in bowl 1034 creates a siphon effect in trapway
1038, whereby fluid and other contents of bowl 1034 are pulled or
suctioned out of bowl 1034 and into trapway 1038 and the drain (not
shown).
As shown in FIGS. 35 and 36, at full travel, first end 1154 of
lever arm 1150 slips past piston lever 1152. As such, piston lever
1152 is clear of lever arm 1150 and may no longer be in contact
therewith. Second end 1156 of lever arm 1150 is then able to pivot
downwardly within channel 1158 to its original position due to its
weight. Even though lever arm 1150 begins to move downwardly within
channel 1158, flapper 1106 may remain in an open position while
water is in tank 1020. More particularly, due to buoyancy, flapper
1106 may initially remain open when water is in tank 1020. However,
as the water level in tank 1020 decreases, flapper 1106 may close
due to a loss of buoyancy and a decrease in the velocity of the
water flowing from tank 1020 into bowl 1034. For example, flapper
1106 may include a plurality of holes (not shown) which allow water
to flow into flapper 1106, thereby decreasing its buoyancy. As
such, flapper 1106 may move downwardly through the water in tank
1020 and close while some water is still in tank 1020. The holes in
flapper 1106 may be arranged according to predetermined conditions
of the flush cycle, such as flush volume (e.g., 1.28 gallons/flush)
and the desired duration of the flush cycle. Flush valve assembly
1100 is closed when flapper 1106 is seated on shoulder 1186 of
frame 1164, which then allows water from tank fill tube 1094 to
remain water in tank 1020.
After flush valve assembly 1100 closes, tank 1020 and bowl 1034 may
be refilled with water. In order to refill tank 1020 and bowl 1034
after toilet 1010 has been flushed, electrically-operable valve
assembly 1048 of fill valve assembly 1040 remains in the open
position such that refill outlet 1044 and flush actuator outlet
1046 remain open. Water from supply tube 1036 flows through refill
outlet 1044, into outlet tube 1090, and through bowl refill tube
1092 in order to flow through overflow tube 1192 and into bowl 1034
via flush tube 1104. As detailed herein, lower end 1198 of overflow
tube 1192 is fluidly coupled to flush tube 1104 below flapper 1106
such that water from overflow tube 1192 may flow into bowl 1034
when flush valve assembly 1100 is closed.
While bowl 1034 is being refilled, water in outlet tube 1090 also
flows into tank refill tube 1094 in order to replenish the water in
tank 1020. With flush valve assembly 1100 in the closed position,
the water flowing from tank refill tube 1094 remains in tank 1020.
Tank sensor 1194 or 1194' may be used to indicate to controller
1208 when tank 1020 has been sufficiently replenished with water.
Fill valve assembly 1040 may be calibrated such that bowl 1034 and
tank 1020 are sufficiently replenished with water at approximately
the same time. Any excess water in tank 1020 may flow into overflow
tube 1192, through flush tube 1104, and into bowl 1034 in order to
spill over into trapway 1038. However, under normal or correct
operation of tank sensor 1194 or 1194', there is no excess water in
tank 1020.
Flush actuator assembly 1108 may remain pressurized when inlet 1042
and outlets 1044 and 1046 of fill valve assembly 1040 are open,
such that diaphragm 1122, piston 1138, and piston rod 1140 remain
depressed. In order to relieve the pressure in flush actuator
assembly 1108, electrically-operable valve assembly 1048 moves to
the closed position. With particular reference to FIG. 25A, a
magnetic force is no longer generated and the bias of spring 1078
pushes armature 1076 away from pole 1074. As such, pilot hole 1066
is sealed, thereby pressurizing diaphragm 1062 and preventing water
flow between valve seat 1061 and diaphragm 1062. More particularly,
the force behind diaphragm 1062 overcomes the force at the front of
diaphragm 1062 (i.e., the force created by the water at inlet 1042)
such that diaphragm 1062 does not flex in response thereto.
With inlet 1042 sealed, the water depressing diaphragm 1122 may
flow upward through flush actuator outlet 1046 in order to be
released through refill outlet 1044 after tank 1020 and bowl 1034
have been refilled. Alternatively, fill valve assembly 1040 may
include a separate bleed hole (not shown) to release the water in
flush actuator assembly 1108. By reducing the water pressure in
flush actuator assembly 1108, diaphragm 1122, piston 1138, spring
1136, and piston rod 1140 move upwardly due to the bias of spring
1136, as shown in FIGS. 37-39. This upward movement allows piston
lever 1152 to rotate over first end 1154 of lever arm 1150 and
return to its original position (FIGS. 33 and 39). Before and after
a flush cycle is initiated, piston lever 1152 is not in contact
with lever arm 1150, however, lever arm 1150 may remain positioned
within channel 1158 of post 1160 before, during, and after a flush
cycle.
Piston lever 1152 may not be in contact with lever arm 1150 at the
end of the flush cycle and, as such, it may be necessary for a user
to wait until the pressure in flush actuator assembly 1108 has been
relieved before another flush cycle may be initiated. Alternative
embodiments of controller 1208 may be configured to send a signal
to electrically-operable valve assembly 1048 in order to initiate
an additional flush cycle before tank 1020 and bowl 1034 have been
fully refilled.
Controller 1208 may be configured with a "timer" or "shut off"
function which turns off fill valve assembly 1040 after being open
for a predetermined time with no signal from tank sensor 1194 or
1194'. For example, if tank 1020 has not been refilled with water
within a predetermined duration of time (e.g., two minutes). In
particular, if tank sensor 1194 or 1194' malfunctions and does not
indicate to controller 1208 that water in tank 1020 is at the level
of sensor 1194 or 1194', then water will continuously flow from
tank 1020 into bowl 1034 through overflow tube 1192. As such, the
timer function of controller 1208 is a "backup" to tank sensor 1194
or 1194' to prevent water from continuously flowing into bowl 1034
if the water level in tank 1020 cannot be determined within a
predetermined length of time after a flush cycle has been
initiated.
Indicator 1110 may include a lens in order to be illuminated with a
light source (e.g., a light-emitting diode ("LED")) or other
device. As such, at least a portion of indicator 1110 may be
illuminated according to certain applications and conditions of
toilet 1010. For example, controller 1208 may illuminate indicator
1110 during certain hours, such as at night, or when the lavatory
is dark. Indicator 1110 also may include a photo sensor to detect
the absence of light.
Additionally, controller 1208 may illuminate indicator 1110 when it
is time to change battery 1116. Indicator 1110 is configured to
produce a plurality of colors in both solid and flashing form. For
example, indicator 1110 may be illuminated with a solid blue color
to indicate that toilet 1010 is operating normal, a solid green
color to indicate a leak in tank 1020, a solid and/or flashing red
color to indicate a low battery warning, a flashing blue color to
indicate an overflow condition, a flashing green color to indicate
a combined leak and overflow condition, a yellow or orange color to
indicate a cleaning condition or mode, and a purple color to
indicate that the fill time for tank 1020 was exceeded. Other
colors and indications are contemplated for other modes.
In operation, indicator 1110 illuminates when a user triggers flush
actuation sensor 1112 through indicator 1110. Indicator 1110
remains illuminated during a flush cycle and may turn off, for
example, when tank sensor 1194 or 1194' signals controller 1208
that tank 1020 is full. Alternatively, if a flush cycle is not
initiated (e.g., when an overflow condition is sensed), indicator
1110 will remain illuminated for a predetermined amount of
time.
Referring to FIGS. 41-44, an alternative embodiment of toilet 1010
includes a handle assembly 1300 coupled to tank 1020' for
initiating a flush cycle. The alternative embodiment of toilet 1010
may include many of the similar features detailed above, wherein
like reference numbers identify similar components. Handle assembly
1300 is operably coupled to flush valve assembly 1100' through a
coupling device, illustratively a chain 1302. The coupling device
also may be a wire, line, rod, or other similar component for
operably coupling handle assembly 1300 to flapper 1106'. As is
detailed above, flush valve assembly 1100' includes flush tube
1104' and flapper 1106'. Flapper 1106' is coupled to chain 1302
with conventional fasteners. Overflow tube 1192 is fluidly coupled
to flush tube 1104' through bracket 1204'.
As shown in FIGS. 42A-C, handle assembly 1300 includes a handle
1304, washers 1306 and 1308, a plurality of couplers,
illustratively a threaded coupler 1310 and nuts 1312 and 1314, a
lever arm 1316, a blocking pin assembly 1318, and a housing 1320.
Handle assembly 1300 is supported on tank 1020' such that handle
1304 is positioned outwardly from tank 1020' and housing 1320 is
positioned within tank 1020'. A post 1322 of handle 1304 extends
through an aperture (not shown) in tank 1020' in order to coupled
with lever arm 1316 to operate flush valve assembly 1100'. In
particular, a first end 1332 of lever arm 1316 is received within
an aperture 1334 of threaded coupler 1310 and an aperture 1336 of
post 1322. A second end 1338 of lever arm 1316 is coupled to chain
1302. Lever arm 1316 includes a generally right-angle bend adjacent
first end 1332 in order to extend lever arm 1316 toward chain 1302
and flapper 1106'.
Coupler 1310 is fixed to tank 1020' by a mounting portion 1328.
Illustratively, mounting portion 1328 defines a square
cross-section and the aperture in tank 1020' also may define a
square. Threaded portion 1330 of threaded coupler 1310 is received
through aperture 1324 of washer 1306 and an aperture 1326 of washer
1308 and is threadedly coupled with nut 1312 and nut 1314 to fix
coupler 1310 to tank 1020'. As such, coupler 1310 does not rotate
relative to tank 1020'. As shown in FIG. 41, nut 1314 may be
positioned outside of housing 1320 when coupled with threaded
portion 1330, or alternatively, nut 1314 may be positioned within
housing 1320 when coupled with threaded portion 1330. Nuts 1312,
1314 allow handle assembly 1300 to accommodate varying thicknesses
of the walls of various tanks.
Coupler 1310 also is coupled to housing 1320. Housing 1320 includes
an upper housing member 1340 and a lower housing member 1342. Upper
and lower housing members 1340, 1342 are coupled together by
conventional means (e.g., fasteners, welds, rivets, adhesive).
Lower housing member 1342 includes an upstanding member 1345 which
has a groove 1347. When threaded portion 1330 extends along a
surface 1344 of lower housing member 1342, a rib 1319 on coupler
1310 (FIG. 42B) is received within groove 1347. When rib 1319 is
positioned within groove 1347, housing 1320 is fixed to coupler
1310. As such, housing 1320 also is fixed to tank 1020' because
coupler 1310 is fixed to tank 1020'. Therefore, coupler 1310
prevents housing 1320 from rotating when handle 1304 is depressed
by a user.
Housing 1320 further supports pin assembly 1318, which includes a
pin 1346 and a motor assembly or an electrically-operable valve
assembly, illustratively a solenoid valve 1348. Solenoid valve 1348
is electrically coupled to a controller, for example controller
1208 (FIG. 40), in order to control the movement of handle 1304.
Controller 1208 also may be in electrical communication with bowl
sensor 1210 (FIG. 40) in order to detect an overflow condition in
bowl 1034 (FIGS. 20 and 21). Pin assembly 1318 is supported on a
portion 1350 of housing 1320, which is elevated relative to cut-out
portion 1344. As such, pin assembly 1318 is elevated relative to
lever arm 1316.
During operation, if no overflow condition is detected by bowl
sensor 1210, handle assembly 1300 is in a flush position and
controller 1208 allows handle 1304 to rotate. As such, when a user
desires to initiate a flush cycle for toilet 1010, handle 1304 is
depressed. Handle 1304 and lever arm 1316 rotate together relative
to coupler 1310, such that the rotation of handle 1304 also causes
first end 1332 of lever arm 1316 to rotate through post 1322 of
handle 1304. More particularly, first end 1332 of lever arm 1316
rotates in a counter-clockwise direction in housing 1320 and second
end 1338 rotates upwardly in tank 1020'. The upward rotation of
second end 1338 pulls up on chain 1302 and, therefore, on flapper
1106'. As such, flush valve assembly 1100' is opened and water from
tank 1020' flows through flush tube 1104' and into bowl 1034 (FIG.
20). As shown in FIG. 44, pin 1346 is retracted within solenoid
valve 1348 and, therefore, does not interfere with the rotation of
lever arm 1316 when handle 1304 is depressed by a user.
The rotation of handle 1304 may be limited by a protrusion 1313 on
an end 1311 of coupler 1310. More particularly, handle 1304
includes surfaces 1317a and 1317b, which are spaced apart from each
other and extend generally outward from post 1322. Protrusion 1313
is received within a slot of handle 1304 defined by surfaces 1317a,
1317b. As such, when handle 1304 rotates, the downward movement of
handle 1304 is stopped when surface 1317a contacts protrusion 1313.
Additionally, the upward movement of handle 1304 is stopped when
surface 1317b contacts protrusion 1313.
However, as shown in FIG. 43, if an overflow condition is detected
by bowl sensor 1210, handle assembly 1300 is in an overflow
position and controller 1208 prevents rotation of handle 1304. In
particular, controller 1208 actuates solenoid valve 1348,
illustratively a latching-type solenoid valve, which projects pin
1346 outwardly such that pin 1346 is positioned above lever arm
1316. As such, pin 1346 interferes with the rotation of lever arm
1316. As shown in FIG. 43, pin 1346 prevents second end 1338 of
lever arm 1316 from rotating upwardly. As such, when a user desires
to initiate a flush cycle after an overflow condition is detected,
the user will not be able to depress handle 1304. Rather, as the
user attempts to depress handle 1304 and second end 1338 of lever
arm 1316 attempts to rotate upwardly, pin 1346 prevents such
rotation. Therefore, the user cannot fully depress handle 1304 and
flapper 1106' does not move away from flush tube 1104'. Pin 1346
prevents the flush cycle when an overflow condition is
detected.
Once an overflow condition is no longer detected by bowl sensor
1210 (FIG. 40), controller 1208 signals solenoid valve 1348 to
retract pin 1346 such that second end 1338 is allowed to rotate
and, therefore, handle 1304 may be depressed by the user.
Referring to FIGS. 45-49, an alternative embodiment handle assembly
1300' is coupled to tank 1020' for initiating a flush cycle. The
alternate embodiment handle assembly 1300' may include many of the
similar features detailed above, wherein like reference numbers
identify similar components. Handle assembly 1300' is operably
coupled to flush valve assembly 1100' through a coupling device,
illustratively a chain 1302 (FIG. 41). Flapper 1106' is coupled to
chain 1302 with conventional fasteners.
As shown in FIGS. 46 and 47, handle assembly 1300' includes a
handle 1304' having a mounting portion 1328' and a post 1322', a
plate 1358, a locating pin 1364 extending from plate 1358, blocking
pin assembly 1318', a plunger 1370, and a power output assembly,
illustratively a motor assembly 1396. To couple handle 1304' with
tank 1020', post 1322' is received through an aperture 1352 in tank
1020' such that mounting portion 1328' is positioned within
aperture 1352. Illustratively, both mounting portion 1328' and
aperture 1352 define a square in cross-section. Post 1322' is
further received through an aperture 1360 in plate 1358 in order to
be secured thereto with nut 1312'. Handle 1304' is operable coupled
to flush valve assembly 1100' through lever arm 1316 and chain 1302
(FIG. 41). As such, rotation of handle 1304' causes lever arm 1316
to rotate and pull up on chain 1302 and flapper 1106' to initiate a
flush cycle.
Plate 1358 is positioned on tank 1020' using locating pin 1364,
which is positioned within an aperture 1356 of tank 1020. Plate
1358 is coupled to motor assembly 1396 through legs 1366 extending
from plate 1358. Legs 1366 are received within apertures 1380 on
motor assembly 1396. Battery 1116 provides power to controller 1208
for operating motor assembly 1396. Motor assembly 1396 also is
configured to receive an electrical signal from controller 1208
(FIG. 40) in order to selectively operate motor assembly 1396 in
response to signals from bowl sensor 1210 (FIG. 40) which may
indicate an overflow condition in bowl 1034 (FIG. 21).
Pin assembly 1318' is supported by plate 1358 and includes a pin
1346' and a body portion 1368. Body portion 1368 includes flanges
1390. Pin 1346' extends from body portion 1368 and is received
through an aperture 1362 on plate 1358. Aperture 1362 is aligned
with an aperture 1354 on tank 1020'. As shown in FIG. 47, a guide
member 1384 extends rearwardly from plate 1358 and is configured to
receive pin assembly 1318' through aperture 1394. To properly
position pin assembly 1318', guide member 1384 includes grooves
1392 which receive flanges 1390. Grooves 1392 fix the rotation of
body portion 1368 but allows body portion 1368 to axially slide
therein. As such, grooves 1392 prevent rotation of body portion
1368 when plunger 1370 is rotated by motor assembly 1396, as
detailed herein.
Body portion 1368 includes an aperture 1386 having internal threads
for threadedly coupling with external threads 1372 of plunger 1370.
Plunger 1370 is received within aperture 1386 of pin assembly 1318'
(FIG. 47) and further includes a flange 1374 and a protrusion 1376.
Illustratively, flange 1374 is intermediate threads 1372 and
protrusion 1376. Protrusion 1376 is received within a channel 1378
of motor assembly 1396 (FIG. 46). Channel 1378 includes an internal
profile generally corresponding to the external profile of
protrusion 1376. Channel 1378 further includes a stop surface 1388
that abuts flange 1374 when protrusion 1372 is received within
channel 1378.
In operation, if no overflow condition is detected by bowl sensor
1210, handle assembly 1300' is in a flush position and controller
1208 allows handle 1304' to rotate. As such, when a user desires to
initiate a flush cycle for toilet 1010, handle 1304' is depressed.
The rotation of handle 1304' also causes lever arm 1316 to rotate,
thereby pulling up on chain 1302 and, therefore, on flapper 1106'
(FIG. 41). As such, flush valve assembly 1100' is opened and water
from tank 1020' flows through flush tube 1104' and into bowl 1034
(FIG. 20). As shown in FIG. 48, pin 1346' is retracted and does not
extend from aperture 1362 of plate 1358 and aperture 1354 of tank
1020'. Therefore, pin 1346' does not interfere with the rotation of
handle 1304', and hence lever arm 1316, when handle 1304' is
depressed by a user. Also, when in the flush position, body portion
1368 of pin assembly 1318' abuts flange 1374 of plunger 1370 to
prevent pin 1346' from extending beyond aperture 1354 of tank
1020'.
However, as shown in FIG. 49, if an overflow condition is detected
by bowl sensor 1210, handle assembly 1300' is an overflow position
and controller 1208 prevents rotation of handle 1304'. In
particular, controller 1208 actuates motor assembly 1396 to project
pin 1346' outwardly from plunger 1370 such that pin 1346' extends
into handle 1304'. As such, pin 1346' interferes with the rotation
of handle 1304'. As shown in FIG. 49, protrusion 1376 of plunger
1370 remains within channel 1378 such that flange 1374 of plunger
abuts stop surface 1388 of channel 1378. However, motor assembly
1396 causes channel 1378 and, therefore, plunger 1370 to rotate.
The rotation of plunger 1370 moves pin assembly 1318' outward from
body portion 1368 and toward handle 1304' because the internal
threads at apertures 1386 of pin assembly 1318' rotate against
external threads 1372 on plunger 1370. As such, pin assembly 1318'
moves toward handle 1304' such that body portion 1368 abuts plate
1358. When body portion 1368 abuts plate 1358, pin 1346' extends
from aperture 1362 of plate 1358 and aperture 1354 of tank 1020'
and is positioned to contact a rear portion of handle 1304'. As
such, when a user attempts to depress handle 1304', handle 1304'
contacts pin 1346' which prevents handle 1304' from rotating.
Therefore, when a user desires to initiate a flush cycle after an
overflow condition is detected, the user will not be able to
depress handle 1304'.
Once an overflow condition is no longer detected by bowl sensor
1210 (FIG. 40), controller 1208 signals motor assembly 1396 to
retract pin assembly 1318' such that body portion 1368 is spaced
apart from plate 1358. For example, motor assembly 1396 may rotate
in a reverse direction to retract pin assembly 1318' and move body
portion 1368 to abut flange 1374 of plunger 1370. Therefore, handle
1304' is allowed to rotate when depressed by the user.
Referring to FIGS. 50-53, a further alternative embodiment handle
assembly 1300'' is coupled to tank 1020' for initiating a flush
cycle. The alternate embodiment handle assembly 1300'' may include
many of the similar features detailed above, wherein like reference
numbers identify similar components. Handle assembly 1300'' is
operably coupled to flush valve assembly 1100' through lever arm
1316 and a coupling device, illustratively chain 1302 (FIG. 41).
Flapper 1106 is coupled to chain 1302 with conventional
fasteners.
First end 1332 of lever arm 1316 is operably coupled to a handle
1304'' of handle assembly 1300'' and second end 1338 of lever arm
1316 is coupled to chain 1302. Conventionally, handle 1304''
rotates when a user depresses handle 1304'' to initiate a flush
cycle, which causes second end 1338 of lever arm 1316 to rotate
upwardly and pull up on chain 1302 and flapper 1106'. When flapper
1106' is spaced apart from flush tube 1104', a flush cycle is
initiated because water from tank 1020' (FIG. 41) flows into bowl
1034 (FIG. 20) through flush tube 1104'.
As shown in FIGS. 50 and 51, handle assembly 1300'' includes handle
1304'', coupler 1310, washers 1306 and 1308, nuts 1312 and 1314'',
a rod 1400, a first clutch plate 1408, a spring 1410, a second
clutch plate 1412, a plunger 1428 having a retractable tip 1432,
and housing 1320'' having front portion 1402 and rear portion 1404.
Post 1322'' of handle 1304'' is received within an aperture 1398
(FIGS. 52 and 53) of coupler 1310 and washers 1306, 1308 are
positioned generally adjacent mounting portion 1328 of coupler
1310. Mounting portion 1328 may be received through an aperture
(not shown) in tank 1020' (FIG. 41) to couple handle assembly
1300'' to tank 1020' with nut 1312. Nut 1314'' also is threadedly
coupled with threaded portion 1330 of coupler 1310 in order to
secure housing 1320'' to tank 1020'. In particular, nut 1314''
snaps onto housing 1320'' when resilient fingers 1405 of front
portion 1402 are frictionally retained on the inner diameter of nut
1314''. Fingers 1405 are separated by grooves 1407 which receive
projections 1321 on coupler 1310. As such, coupler 1310 is fixed to
housing 1320''. Coupler 1310 also is fixed to tank 1020' and,
therefore, housing 1320'' is fixed to tank 1020''. In this
arrangement, housing 1320'' does not rotate when handle 1304'' is
depressed.
Rod 1400 is received within aperture 1334 of coupler 1310 and
extends into post 1322'' of handle 1304'' through aperture 1336. A
portion of rod 1400 also is supported in housing 1320'', which
includes a front portion 1402 and a rear portion 1404 coupled
together with fasteners 1430. In particular, rod 1400 is received
through an aperture 1406 in front portion 1402 and is operably
coupled to first and second clutch plates 1408, 1412.
Illustratively, rod 1400 extends through an aperture 1434 of first
clutch plate 1408 and is configured to be received within first and
second recesses 1436, 1438 of second clutch plate 1412 (FIGS. 52
and 53). Rod 1400 is rotationally fixed to first clutch plate 1408
but is spaced apart from second clutch plate 1412.
Spring 1410 is positioned intermediate first and second clutch
plates 1408, 1412. More particularly, first and second clutch
plates 1408, 1412 are generally received within spring 1410 such
that spring 1410 generally extends around detents 1442 of first
clutch plate 1408 and detents 1444 of second clutch plate (FIGS.
51-53).
Second clutch plate 1412 includes a flange 1446 and a tubular
member 1414 having a channel 1416. Channel 1416 is configured to
receive lever arm 1316 therein. Lever arm 1316 is secured within
channel 1416 with brackets 1418 and 1420, which are coupled
together at first end 1332 of lever arm 1316. Alternatively,
brackets 1418, 1420 may be integrally formed with lever arm 1316.
Lever arm 1316 extends through opening 1426 in rear portion 1404 of
housing 1320'' in order to couple with chain 1302 (FIG. 41) for
operating flush valve assembly 1100'.
Rear portion 1404 of housing 1320'' further supports plunger 1428.
Plunger 1428 extends through an aperture 1424 in rear portion 1404
and is secured thereto with a coupler, illustratively a nut 1422.
Plunger 1428 may be electrically coupled to controller 1208 (FIG.
40) in order to selective retract and project tip 1432 from plunger
1428 in response to an overflow condition, as further detailed
herein. For example, plunger 1428 may include a solenoid valve or a
motor assembly (not shown) electrically coupled to controller 1208
for controlling the movement of tip 1432.
In operation, if no overflow condition is detected by bowl sensor
1210, handle assembly 1300'' is in a flush position and controller
1208 allows handle 1304'' to rotate. As such, when a user desires
to initiate a flush cycle for toilet 1010, handle 1304'' is
depressed downwardly. The rotation of handle 1304'' also causes
lever arm 1316 to rotate within opening 1426 of rear portion 1404
of housing 1320'', thereby pulling up on chain 1302 and, therefore,
on flapper 1106' (FIG. 41). As such, flush valve assembly 1100' is
opened and water from tank 1020' flows through flush tube 1104' and
into bowl 1034 (FIG. 20).
As shown in FIG. 53, when handle 1304'' is allowed to rotate, first
and second clutch plates 1408, 1412 are coupled together such that
detents 1442 of first clutch plate 1408 frictionally mate with
detents 1444 of second clutch plate 1412 in order to allow handle
1304'' to rotate. In an unactuated position, tip 1432 projects from
plunger 1428. Tip 1432 contacts tubular member 1414 and overcomes
the bias of spring 1410 such that first and second clutch plates
1408, 1412 are in contact. As such, lever arm 1316 is rotate within
opening 1426 of rear portion 1404 when handle 1304'' is depressed.
When in the flush position, rod 1400 is received within first and
second recesses 1436, 1438 of second clutch plate 1412 and is
adjacent stop surface 1440 of second clutch plate 1412.
However, as shown in FIG. 52, if an overflow condition is detected
by bowl sensor 1210, handle assembly 1300'' is in an overflow
position and controller 1208 prevents rotation of handle 1304''. In
particular, controller 1208 actuates the solenoid valve or motor
assembly (not shown) in order to retract tip 1432 within plunger
1428. As such, when tip 1432 no longer applies pressure to second
clutch plate 1412, the bias of spring 1410 moves second clutch
plate 1412 away from first clutch plate 1408. Second clutch plate
1412 also moves away from rod 1400 such that rod 1400 is spaced
apart from stop surface 1440 of second clutch plate 1412.
Additionally, when second clutch plate 1412 moves away from first
clutch plate 1408, lever arm 1316 moves rearwardly within an
extension 1450 of opening 1426 of rear portion 1404 of housing
1320''. As such, when a user attempts to depress handle 1304'',
handle 1304'' does not rotate because lever arm 1316 is no longer
rotationally coupled to handle 1304''. Therefore, handle 1304'' may
rotate without initiating rotation in lever arm 1316.
Alternatively, second clutch plate 1412 may remain engaged with
first clutch plate 1408. When tip 1432 is retracted within plunger
1428, both first and second clutch plates 1408, 1412 may move
rearwardly in housing 1320''. As such, lever arm 1316 also moves
rearwardly. When handle 1304'' is depressed, lever arm 1316 may
contact an upper surface 1452 of extension 1450, which prevents
lever arm 1316 from rotating upwardly. As such, flush valve
assembly 1100' does not open. Therefore, when a user desires to
initiate a flush cycle after an overflow condition is detected, the
user will not be able to depress handle 1304''.
Once an overflow condition is no longer detected by bowl sensor
1210 (FIG. 40), controller 1208 disengages the solenoid valve or
motor assembly (not shown) and tip 1432 again projects from plunger
1428 to engage tubular member 1414 and moves second clutch plate
1412 toward first clutch plate 1408. Handle 1304'' is allowed to
rotate when depressed by the user because lever arm 1316 moves
forward from extension 1450 and into opening 1426 which allows
second end 1338 to rotate upwardly.
Referring to FIGS. 54-62, an alternative embodiment of toilet 1010
of FIG. 20 is shown as toilet 1510. The alternative embodiment
toilet 1510 includes many similar features to those of toilet 10
and toilet 1010 detailed above, wherein like reference numbers
identify similar components except as described below. Toilet 1510
includes a tank 1520, base 1032 (FIG. 20), bowl 1034 (FIG. 20), an
inlet tube, illustratively a water supply tube 1536, an outlet
tube, illustratively trapway 1038 (FIG. 21), a fill valve assembly
1540, a flush valve assembly 1600, and an overflow assembly 1690.
Illustratively, toilet 1510 is a tank-type, gravity-fed toilet
similar to toilet 10 (FIG. 1) and toilet 1010 (FIG. 20) described
herein.
Tank 1520 includes a lid 1522, a bottom surface 1529, a front
surface 1524, a rear surface 1526, a first side 1528, and a second
side 1530. Tank 1520 may be comprised of a ceramic, metallic, or
polymeric material, for example porcelain, stainless steel, or
plastic composite materials. Rear surface 1526 includes an external
recessed channel 1527 which guides supply tube 1536 into tank 1520
above the water level in tank 1520. As shown in FIG. 54, supply
tube 1536 is in fluid communication with flush valve assembly 1600
and overflow assembly 1690 through fill valve assembly 1540. In
particular, supply tube 1536 is fluidly coupled to a water supply
(not shown) in order to flow water into fill valve assembly 1540,
as further detailed herein.
As shown in FIGS. 55-60, a housing 1550 supports both a flush
actuator assembly 1608 and fill valve assembly 1540. Referring to
FIGS. 55 and 60, fill valve assembly 1540 includes an inlet 1542, a
refill outlet 1544, a flush actuator outlet 1546, and an
electrically-operable valve assembly 1548. Housing 1550 may include
an upper portion 1552 and a lower portion 1554. Illustratively,
upper portion 1552 is coupled to lower portion 1554 with snap
fingers 1762 (FIGS. 55 and 56). Alternatively, upper portion 1552
may be integral with lower portion 1554, or may be coupled thereto
with other conventional fasteners. Upper portion 1552 supports
inlet 1542, outlets 1544, 1546, and electrically-operable valve
assembly 1548.
As shown in FIGS. 55 and 60, inlet 1542 is fluidly coupled with
supply tube 1536. More particularly, inlet 1542 may include
external threads 1556 that threadedly couple with supply tube 1536.
The connection between supply tube 1536 and inlet 1542 may occur
within tank 1520.
Inlet 1542 may further support a flow restrictor 1562 (FIGS. 57 and
60). Illustratively, flow restrictor 1562 is a
pressure-compensating flow restrictor. Flow restrictor 1562 may be
positioned intermediate electrically-operable valve assembly 1548
and supply tube 1536, such that flow restrictor 1562 is upstream of
electrically-operable valve assembly 1548. In one embodiment, flow
restrictor 1562 may be configured to control the flow rate at
approximately 2.5 gallons/minute. By controlling the flow rate,
flow restrictor 1562 assists in maintaining a constant pressure
within fill valve assembly 1540, as detailed further herein.
Additionally, fill valve assembly 1540 may include a check valve
1578, as shown in FIG. 57. If a vacuum occurs at inlet 1542 of fill
valve assembly 1540, check valve 1578 is configured to "break" the
vacuum, thereby preventing backflow, or water flow in a reverse
direction through electrically-operable valve assembly 1548 and
back into supply tube 1536.
Referring to FIG. 60, electrically-operable valve assembly 1548 is
positioned within housing 1550 and is in fluid communication with
inlet 1542, refill outlet 1544, and flush actuator outlet 1546.
Electrically-operable valve assembly 1548 is threadedly coupled to
upper portion 1552 of housing 1550 through external threads 1584
and internal threads 1586. Electrically-operable valve assembly
1548 may be, for example, an electromechanical valve, and more
particularly, may be a solenoid valve of the latching-type.
Exemplary electrically-operable valve assembly 1548 is the same as
electrically-operable valve assembly 1048 of FIGS. 24-25B and 28
and, as such, may include a filter 1570, a seal 1582, and a body
portion 1560 supporting a valve seat, a diaphragm, a shaped
portion, a pilot hole, a seal, a magnet, a pole, an armature, and a
spring. Electrically-operable valve assembly 1548 operates in the
same manner as electrically-operable valve assembly 1048 (FIGS.
24-25B and 28). Electrically-operable valve assembly 1548 further
includes electrical wires 1588 extending from body portion 1560 for
supplying power to electrically-operable valve assembly 1548.
Electrically-operable valve assembly 1548 also may be in electric
communication with a controller 1708 (FIG. 61) through electrical
wires 1588. During operation of toilet 1510, electrically-operable
valve assembly 1548 receives signals from controller 1708 to
control the flow of water from inlet 1542 to refill outlet 1544 and
flush actuator outlet 1546, as further detailed herein and in U.S.
Provisional Patent Application Ser. No. 61/610,205, filed on Mar.
13, 2012, and U.S. Provisional Patent Application Ser. No.
61/722,074, filed on Nov. 2, 2012, the complete disclosures of
which are expressly incorporated by reference herein. For example,
electrically-operable valve assembly 1548 may be actuated by
controller 1708 in order to flow water from inlet 1542 into outlets
1544 and 1546.
Referring to FIG. 55, the illustrative embodiment of fill valve
assembly 1540 includes two outlets 1544 and 1546, however, any
number of outlets may be included to accommodate particular
applications of fill valve assembly 1540. Illustratively, refill
outlet 1544 may be approximately perpendicular to inlet 1542.
Additionally, as shown in FIGS. 54-57, refill outlet 1544 may be
fluidly coupled to a bowl refill tube 1592 and a tank refill tube
1594. In the illustrative embodiment of FIG. 57, tank refill tube
1594 has a larger diameter than bowl refill tube 1592.
Tank refill tube 1594 includes an upper portion 1594a and a lower
portion 1594b. Upper portion 1594a may be directly coupled to
refill outlet 1544 with a sealing member, illustratively an o-ring
1593 (FIG. 57). In the illustrative embodiment of FIG. 57, lower
portion 1594b is coupled to upper portion 1594a at an approximately
right angle. Lower portion 1594b of tank refill tube 1594 extends
downwardly from upper portion 1594a such that a bottom surface of
lower portion 1594b is adjacent a flapper 1606 of flush valve
assembly 1600 (FIGS. 54-56).
Illustratively, tank refill tube 1594 includes a first nipple 1590,
a second nipple 1591, and a conduit 1596 (FIGS. 55-59). First and
second nipples 1590, 1591 and conduit 1596 may be integrally formed
with tank refill tube 1594 or, alternatively, may be coupled
thereto with conventional fasteners. As shown in FIGS. 55 and 57,
first nipple 1590 extends from upper portion 1594a of tank refill
tube 1594 and second nipple 1591 extends from conduit 1596. Lower
portion 1594b may be positioned outward of conduit 1596. Conduit
1596 is coupled to lower portion 1594b with a support member 1598,
as shown in FIG. 56, such that conduit 1596 is generally parallel
to lower portion 1594b. Support member 1598 may be integrally
coupled to tank refill tube 1594 or coupled thereto with
conventional fasteners. A portion of conduit 1596 may be positioned
within an overflow tube 1692 of overflow assembly 1690.
Lower portion 1594b of tank refill tube 1594 also includes a
coupling member 1730, as shown in FIGS. 57 and 59. Illustratively,
coupling member 1730 is integrally coupled to lower portion 1594b
of tank refill tube 1594 and defines a circle in cross-section.
Coupling member 1730 includes a center aperture 1734 which is
configured to assemble around overflow tube 1692. In one
embodiment, the inner diameter of center aperture 1734 is
approximately the same size as the outer diameter of overflow tube
1692. Coupling member 1730 also includes cut-out portions 1732 on
opposing sides of overflow tube 1692. Cut-out portions 1732 are
configured to receive posts 1736 (FIG. 56) on overflow tube 1692.
After posts 1736 are initially received within cut-out portions
1732, coupling member 1730 is configured to rotate about overflow
tube 1692 in order to secure posts 1736 therein. Illustratively,
coupling member 1730 is a twist and lock member for coupling tank
refill tube 1594 to overflow tube 1692.
An upper end of bowl refill tube 1592 is coupled to first nipple
1590 and a lower end of bowl refill tube 1592 is coupled to second
nipple 1591. As shown in FIGS. 55 and 56, when the lower end of
bowl refill tube 1592 is coupled to second nipple 1591, water
within bowl refill tube 1592 flows through second nipple 1591 and
into conduit 1596 in order to refill bowl 1034 (FIG. 20). More
particularly, a portion of the water in upper portion 1594a of tank
refill tube 1594 flows through first nipple 1590, into bowl refill
tube 1592, into conduit 1596, through overflow tube 1692, and into
bowl 1034. In one embodiment, bowl refill tube 1592 is a flexible
polymeric tube with an inner diameter of approximately 0.25 inch.
For example, bowl refill tube 1592 may be comprised of
polyvinylchloride (PVC) material. Bowl refill tube 1592 may be
configured to bend around a portion of tank refill tube 1594 in
order to couple with second nipple 1591. In one exemplary
embodiment, approximately 25% of the water in upper portion 1594a
of tank refill tube 1594 flows into bowl refill tube 1592 to refill
bowl 1034, and approximately 75% of the water in upper portion
1594a flows into lower portion 1594b of tank refill tube 1594 to
refill tank 1520 after toilet 1510 has been flushed.
As shown in FIG. 57, fill valve assembly 1540 further includes a
pressure relief member 1572 adjacent refill outlet 1544. In
particular, pressure relief member 1572 is positioned generally
intermediate electrically-operable valve assembly 1548 and refill
outlet 1544. Pressure relief member 1572 includes a piston member
1574 and a spring 1576. Piston member 1574 includes a central
opening or bleed orifice 1575 (FIG. 62). Piston member 1574 also
may include a sealing member, for example an o-ring, in order to
selectively seal refill outlet 1544 from flush actuator outlet
1546, as detailed further herein.
In operation, pressure relief member 1572 may be biased toward a
closed position in which spring 1576 is not compressed and piston
member 1574 seals against refill outlet 1544. As such, when a flush
cycle is initiated, pressure relief member 1572 may be closed
against refill outlet 1544 such that the water in fill valve
assembly 1540 does not initially flow through refill outlet 1544.
Due to this restriction at refill outlet 1544, pressure may
increase within fill valve assembly 1540, even when the pressure in
supply tube 1536 is low. When the pressure in fill valve assembly
1540 increases to a predetermined amount sufficient to overcome the
bias of spring 1576, piston member 1574 and spring 1576 move away
from refill outlet 1544, thereby opening refill outlet 1544, to
allow water to flow into refill outlet 1544. By opening refill
outlet 1544 at a predetermined pressure, the pressure in fill valve
assembly 1540 may remain constant. For example, the pressure in
fill valve assembly 1540 may be constantly maintained at
approximately 8 psi.
Referring to FIGS. 54-60, fill valve assembly 1540 is operably
coupled to flush valve assembly 1600 through flush actuator outlet
1546. Flush valve assembly 1600 includes a flush tube 1604, flapper
1606, a flush actuator assembly 1608, an indicator 1610, and a
flush actuation sensor 1612 (FIG. 61). Flush actuation sensor 1612
cooperates with indicator 1610 (FIGS. 54 and 61) and a controller
1708 (FIG. 61) to initiate a flush cycle. Illustratively,
controller 1708 and indicator 1610 may be supported by a waterproof
housing or casing 1614 in tank 1520. Casing 1614 and indicator 1610
may be operably coupled to a power source (e.g., a battery 1616)
and are structurally and operationally similar to casing 1114 and
indicator 1110 in FIG. 22.
The illustrative embodiment of fill valve assembly 1540 is
controlled by a controller 1708 (FIG. 61). More particularly,
controller 1708 receives a signal from a bowl sensor 1760 (FIG. 61)
coupled to bowl 1034 which determines if an overflow condition has
occurred in bowl 1034 (FIG. 21). Bowl sensor 1760 is configured to
detect an overflow condition, such as when the water level in bowl
1034 rises above a predetermined, critical level. In particular,
bowl sensor 1760 may prevent operation of fill valve assembly 1540
when an overflow condition is detected. Therefore, bowl sensor 1760
also may prevent operation of flush actuator assembly 1608 and
flush valve assembly 1600 when an overflow condition is detected.
Alternatively, when an overflow condition is not signaled by bowl
sensor 1760, controller 1708 (FIG. 61) may send a signal to
electrically-operable valve assembly 1548 to initiate a flush
cycle. Bowl sensor 1760 also may be configured to detect a water
leak in bowl 1034 and signal a leak condition to controller 1708.
Controller 1708, through an indicator 1610 on tank 1520, may signal
a user that bowl 1034 has a leak condition and/or an overflow
condition.
Bowl sensor 1760 may be a piezoelectric element, an infrared
sensor, a radio frequency ("RF") device, a capacitive sensor, a
float device, an ultrasound device, or an electric field, for
example. Illustratively, bowl sensor 1760 is a capacitive sensor.
Bowl sensor 1760 may be comprised of a metallic plate (e.g., brass)
overmolded with a polymeric material (e.g., polyvinylchloride).
Bowl sensor 1760 may be adhered to the back of bowl 1034 (as shown
in FIG. 21). In one embodiment, a foam material also may be coupled
with bowl sensor 1760 on bowl 1034.
Referring to FIG. 60, flush actuator outlet 1546 may be a conduit
extending from housing 1550 to flush actuator assembly 1608. Flush
actuator assembly 1608 is structural and operationally similar to
flush actuator assembly 1108 (FIG. 28) detailed above. For example,
flush actuator assembly 1608 may include a piston rod 1620 coupled
to a diaphragm 1622, a piston 1638, and a retainer plate 1642 with
a screw 1634 or other fastener. A spring 1636 may be positioned
around piston rod 1620 and below piston 1638. Flush actuator
assembly 1608 is generally contained within a cylinder 1624 defined
by housing 1550. Constant water pressure within fill valve assembly
1540 may be used to engage flush actuator assembly 1608 and, more
particularly, may be used to overcome the bias of spring 1636. When
the pressure in fill valve assembly 1540 overcomes the bias of
spring 1636, piston rod 1620, piston 1638, diaphragm 1622, and
retainer plate 1642 move downwardly toward the lower surface of
cylinder 1624. The lower surface of cylinder 1624 may include at
least one aperture (not shown) for releasing or exhausting air from
cylinder 1624 during operation of flush actuator assembly 1608.
During operation of flush actuator assembly 1608, diaphragm 1622
provides a long stroke with minimal friction, which reduces the
minimum amount of friction needed to operate flush actuator
assembly 1608. Because flush actuator assembly 1608 may operate at
a reduced pressure, toilet 1510 may continue to operate even when
the water pressure in supply tube 1536 decreases. Furthermore, the
pressure within fill valve assembly 1540 may be maintained at the
minimum pressure required to overcome the spring bias of spring
1636. As such, the amount of pressure within fill valve assembly
1540 is maintained at a predetermined amount and does not increase
to an amount that may cause damage to fill valve assembly 1540
and/or other components of toilet 1510.
Piston rod 1620 extends downwardly from cylinder 1624 and is
coupled to a pivot assembly 1710 of flush valve assembly 1600. As
shown in FIGS. 54-59, a pivot assembly 1710 includes a support
member 1712, a lever member 1714, a pivot member 1716, and a guide
member 1718. Support member 1712 is coupled to piston rod 1620 and
extends generally around overflow tube 1692. Illustratively, the
lower portion of piston rod 1620 is integral with support member
1712. More particularly, support member 1712 includes opposing
sides 1712a, 1712b which are coupled to piston rod 1620 and extend
generally around overflow tube 1692. Sides 1712a, 1712b of support
member 1712 also extend partially around tank refill tube 1594.
A lower end of support member 1712 is coupled to pivot member 1716.
As shown in FIGS. 56 and 57, the lower end of support member 1712
includes brackets 1720 for supporting pivot member 1716. Pivot
member 1716 is configured to pivot outwardly from brackets 1720.
Illustratively, pivot member 1716 extends around a portion of tank
refill tube 1594 and may be configured to pivot outwardly
therefrom. Pivot member 1716 also includes pivot feet 1722 for
selectively engaging a pair of pivot arms 1750 on flapper 1606, as
detailed further herein.
In addition to pivot member 1716, support member 1712 also is
coupled to lever member 1714. More particularly, lever member 1714
is positioned above support member 1712 and may be frictionally
retained on tank refill tube 1594. Lever member 1714 is configured
to slide along tank refill tube 1594. A lower end of lever member
1714 includes projections 1724 which correspond to recesses 1726 in
support member 1712. As such, when lever member 1714 slides in a
downward direction toward support member 1712, projections 1724 are
received within recesses 1726 such that support member 1712 also
slides in a downward direction along tank refill tube 1594. A tab
1728 is positioned at the upper end of lever member 1714 and,
illustratively, is integrally formed with lever member 1714. Tab
1728 allows a user to manually operate and control the movement of
lever member 1714. For example, in the event of a power loss,
controller 1708 may not operate. However, a user may continue to
operate toilet 1510, at least once, by depressing tab 1728 and
manually sliding lever member 1714 and support member 1712 in a
downward direction.
As shown in FIGS. 55 and 57, guide member 1718 is coupled to tank
refill tube 1594 and includes an upper rail 1718a and a lower rail
1718b. Rails 1718a, 1718b are parallel to each other and extend
generally perpendicularly to tank refill tube 1594. Illustratively,
guide member 1718 is integrally coupled to lower portion 1594b of
tank refill tube 1594. Because tank refill tube 1594 is not
configured to move or slide during operation of toilet 1510, guide
member 1718 also is stationary. Guide member 1718 may be in contact
with sides 1712a, 1712b of support member 1712. As is detailed
further herein, the downward movement of lever member 1714 may be
limited by upper rail 1718a of guide member 1718 and the upward
movement of pivot member 1716 may be limited by lower rail 1718b.
Additionally, if pivot assembly 1710 is in close proximity to any
of surfaces 1524, 1526 or sides 1528, 1520 of tank 1520, rails
1718a, 1718b prevent interference with tank 1520 when pivot
assembly 1710 moves during operation of toilet 1510.
Referring to FIG. 54, overflow assembly 1690 includes overflow tube
1692 and a tank sensor 1694 (FIGS. 55 and 61). Tank sensor 1694 is
configured to detect an overflow condition and is structurally and
operationally the same as tank sensor 1194' of FIG. 31. Overflow
tube 1692 is coupled to flush actuator assembly 1608 through tank
refill tube 1594. Overflow tube 1692 is secured to tank refill tube
1594 with coupling member 1730. Additionally, support member 1712
extends around a portion of overflow tube 1692. Overflow tube 1692
also is fluidly coupled to bowl refill tube 1592 through conduit
1596.
Overflow tube 1692 also is coupled to flush tube 1604 and flapper
1606. In particular, the outlet of overflow tube 1692 is coupled to
flush tube 1604 below flapper 1606 such that water in overflow tube
1692 may flow into bowl 1034 (FIG. 20) regardless of whether
flapper 1606 is closed against flush tube 1604. By coupling
overflow tube 1692 to flush tube 1604, the height of overflow tube
1692 may vary to accommodate various water levels and geometries of
tank 1520 without affecting the operation of flush valve assembly
1600.
Additionally, overflow tube 1692 is coupled to flapper 1606 with
posts 1736, as shown in FIGS. 55 and 56. Posts 1736 may be
integrally coupled with overflow tube 1692 or may be coupled
thereto with conventional fasteners. Posts 1736 engage a pair of
pivot arms 1750 of flapper 1606 and define the pivot location for
flapper 1606. As such, when initiating a flush cycle, flapper 1606
may be lifted or otherwise moved by pivoting flapper 1606 about
posts 1736, as detailed further herein. Illustratively, flapper
1606 may be a tilting or hinged type of flapper and, as such,
flapper 1606 rotates or pivots to open flush tube 1604, rather than
moving axially in a vertical direction. Illustrative flapper 1606
is a chainless flapper that operates by pivoting upwardly.
Referring to FIGS. 54-56, in one embodiment, pivot arms 1750
include a pivot frame 1752. Pivot frame 1752 is positioned inward
of pivot arms 1750 and extends over the upper surface of posts
1736. Pivot frame 1752 includes tabs 1754, which are configured to
engage pivot feet 1722 of pivot member 1716 during a flush cycle.
For example, before a flush cycle, pivot feet 1722 are positioned
above tabs 1754 of pivot frame 1752. During a flush cycle, support
member 1712 and pivot member 1716 move downwardly with the movement
of flush actuator assembly 1608 and pivot feet 1722 contact tabs
1754. Tabs 1754 pivot downwardly and, therefore, pivot frame 1742
and pivot arms 1750 pivot flapper 1606 in an upward direction about
posts 1736.
Flapper 1606 may include a seal 1684 (FIG. 58) that engages a frame
member 1670 coupled to flush tube 1604. In one embodiment, frame
member 1670 is partially positioned within flush tube 1604 and is
threadedly coupled thereto. As shown in FIG. 55, a portion of frame
member 1670 may be positioned above flush tube 1604 and define a
surface for engaging seal 1684 in order to seal the water in tank
1520. Flush tube 1604 is coupled to bowl 1034 (FIG. 21) in the
manner detailed above with respect to flush tube 1104.
Referring to FIGS. 61 and 62, in use, toilet 1510 is operated when
a flush cycle is initiated. More particularly, when a user desires
to flush toilet 1510, the user activates flush actuation sensor
1612 (FIG. 61). For example, a user's hand may be placed in
proximity to (e.g., placed in front of) indicator 1610 in order to
trigger the flush cycle. As such, toilet 1510 is an automatic and
hands-free flush toilet because a user normally initiates a flush
cycle through flush actuation sensor 1612, rather than by
depressing a manual handle or button on toilet 1510. Flush
actuation sensor 1612 receives the user input and sends a signal to
controller 1708 to initiate operation of flush valve assembly 1600
and fill valve assembly 1540. Before initiating the flush cycle,
controller 1708 receives signals from bowl sensor 1760 to determine
if the water level in bowl 1034 (FIG. 21) is above the
predetermined critical water level. If the water level in bowl 1034
is at or below the critical level, then controller 1708 will
initiate the flush cycle. Conversely, if bowl sensor 1760 signals
to controller 1708 that the water level in bowl 1034 is above the
critical level, controller 1708 will not actuate fill valve
assembly 1540 to initiate a flush cycle. In other words, bowl
sensor 1760 is continuously in electric communication with
controller 1708 and transmits a baseline capacitance to controller
1708. The baseline capacitance (e.g., zero capacitance) is
continuously transmitted to controller 1708 until an overflow
condition occurs. When an overflow condition occurs, the
capacitance signal from bowl sensor 1706 increases. Controller 1708
processes the increased capacitance from bowl sensor 1706 by
comparing the increased capacitance to the baseline capacitance.
When controller 1708 determines that the increased capacitance is
greater than the baseline capacitance, controller 1708 transmits a
signal to fill valve assembly to prevent the initiation of a flush
cycle. Additional details of the operation of bowl sensor 1706 and
controller 1708 are disclosed in U.S. patent application Ser. No.
13/798,406 filed on Mar. 13, 2013, the complete disclosure of which
is expressly incorporated by reference herein.
When an overflow condition is detected, water does not flow into or
from tank 1520 during an overflow condition. Illustratively, water
does not flow from inlet 1542 to flush actuator outlet 1546 and,
therefore, flush actuator assembly 1608 does not lift flapper 1606,
which prevents water in tank 1520 from flowing into bowl 1034.
Additionally, water does not flow from inlet 1542 to refill outlet
1544 and, therefore water does not flow into tank 1520 through tank
refill tube 1594 or into bowl 1034 through bowl refill tube
1592.
However, it may be appreciated that exemplary toilet 1510 is
configured to allow a user to flush toilet 1510, at least once,
after an overflow condition has been detected. In particular, the
user may remove lid 1522 of toilet 1510 and manually depress tab
1728 (FIG. 57) in order to manually lift flapper 1606 and open
flush valve assembly 1600. The water in tank 1520 will flow through
flush valve assembly 1600, into bowl 1034, and through trapway 1038
to flush toilet 1510. However, because an overflow condition has
been signaled to controller 1708, controller 1708 may not actuate
fill valve assembly 1540 and, therefore, tank 1520 and bowl 1034
may not be refilled.
When an overflow condition is not detected, controller 1708 sends a
signal to fill valve assembly 1540 in response to the signal from
flush actuation sensor 1612, to initiate the flush cycle. In
particular, electrically-operable valve assembly 1548 is actuated
to allow water from supply tube 1536 to flow into fill valve
assembly 1540. As the water from supply tube 1536 enters inlet
1542, the water flows through flow restrictor 1562 upstream of
electrically-operable valve assembly 1548. In particular, flow
restrictor 1562 is configured to adjust the flow of water through
inlet 1542 to a predetermined flow rate according to the pressure
of the water. Illustratively, flow restrictor 1562 may restrict the
flow rate at inlet 1542 to approximately 2.5 gallons/minute. By
controlling the flow of water upstream of electrically-operable
valve assembly 1548, the pressure within fill valve assembly 1540
may be controlled. Furthermore, because the restriction of flow
restrictor 1562 varies with the parameters of the water (e.g.,
water pressure), flow restrictor 1562 is configured to maintain a
constant flow rate, even when the supply pressure is low.
As the water flows through flow restrictor 1562 and
electrically-operable valve assembly 1548, the water initially
flows only through flush actuator outlet 1546 because pressure
relief member 1572 is closed against refill outlet 1544. As such,
pressure in fill valve assembly 1540 may increase to a
predetermined amount before the pressure within fill valve assembly
1540 overcomes the bias of spring 1576 of pressure relief member
1572. Additionally, as the pressure increases, the bias of spring
1636 of flush actuator assembly 1608 may be overcome such that
diaphragm 1622, piston rod 1620, and retainer plate 1642 move
downwardly in cylinder 1624.
In one embodiment, fill valve assembly 1540 includes both pressure
relief member 1572 and flow restrictor 1562 in order to apply a
constant pressure during a flush cycle. More particularly, flow
restrictor 1562 controls the flow rate and, therefore, the pressure
within fill valve assembly 1540 upstream of electrically-operable
valve assembly 1548 while pressure relief member 1572 controls the
pressure within fill valve assembly 1540 downstream of
electrically-operable valve assembly 1548. For example, without
flow restrictor 1562 and pressure relief member 1572, the pressure
within fill valve assembly 1540 may increase rapidly due to an
uncontrolled flow of water at inlet 1542 and a flow restriction at
refill outlet 1544 caused when bowl refill tube 1592 has a smaller
inner diameter than tank refill tube 1594. As such, the pressure
within fill valve assembly 1540 may increase to amount greater than
that necessary to operate fill valve assembly 1540. Additionally,
the pressure within fill valve assembly 1540 may vary with the
pressure in supply tube 1536. As such, without flow restrictor 1562
and pressure relief member 1572, a constant pressure within fill
valve assembly 1540 may not be maintained. However, with flow
restrictor 1562, the flow rate and, therefore, the pressure at
inlet 1542 may be controlled to minimize any a restriction at
refill outlet 1544.
However, illustrative toilet 1510 requires a predetermined pressure
within fill valve assembly 1540 in order to operate flush actuator
assembly 1608. By closing refill outlet 1544 with pressure relief
member 1572 when a flush cycle is initiated, the water entering
fill valve assembly 1540 only flows through flush actuator outlet
1546 and pressure increases at flush actuator outlet 1546. When the
pressure at flush actuator outlet 1546 increases to the
predetermined amount necessary to overcome the bias of spring 1636,
flush actuator assembly 1608 moves downwardly. In the same way,
when the pressure within fill valve assembly 1540 increases to a
predetermined amount necessary to overcome the bias of spring 1576
(e.g., approximately 8-15 psi), pressure relief member 1572 moves
away from refill outlet 1544, which allows water to flow into bowl
refill tube 1592 and tank refill tube 1594. As such, the pressure
within fill valve assembly 1540 remains constant at that
predetermined pressure as water flows through refill outlet
1544.
Furthermore, because the pressure in fill valve assembly 1540 is
constant, flush actuator assembly 1608, and more particularly
piston rod 1620, applies a constant force to pivot assembly 1710
during a flush cycle. The constant force of piston rod 1620 moves
support member 1712 downwardly. Pivot member 1716 moves downwardly
with support member 1712 and pivot feet 1722 contact tabs 1754 of
pivot frame 1752 on flapper 1606. The constant force applied by
flush actuator assembly 1608 to pivot assembly 1710 is sufficient
to rotate flapper 1606 about posts 1736. In particular, pivot arms
1750 of flapper and pivot frame 1752 pivot about posts 1736 of
overflow tube 1692. When flapper 1606 pivots about posts 1736,
flush tube 1604 opens to allow the water in tank 1520 to flow into
bowl 1034 and flush toilet 1510. Flapper 1606 remains open until
the water flows out of tank 1520 because flapper 1606 is buoyant in
the water. As the water level in tank 1520 decreases, flapper 1606
pivots about posts 1736 and closes against frame member 1670 of
flush tube 1604.
After pivot feet 1722 of pivot member 1716 contact tabs 1754 of
pivot frame 1752, pivot member 1716 is configured to pivot
outwardly from tank refill tube 1594 and support member 1712 such
that pivot feet 1722 do not interfere with the rotation of pivot
frame 1752 or flapper 1606. Additionally, pivot member 1716 is
configured to over-travel pivot frame 1752 and move downwardly past
pivot frame 1752 as flapper 1606 pivots to further ensure that
pivot member 1716 does not interfere with the opening or closing of
flapper 1606.
After flush valve assembly 1600 closes (i.e., flapper 1606 seals
against flush tube 1604), tank 1520 and bowl 1034 may be refilled
with water. In order to refill tank 1520 and bowl 1034,
electrically-operable valve assembly 1548 remains open to allow
water to flow from inlet 1542 to refill outlet 1544 and flush
actuator outlet 1546. With electrically-operable valve assembly
1548 open, flush actuator assembly 1608 remains pressurized and,
therefore, pivot assembly 1710 remains in a downward position.
Water from supply tube 1536 flows through refill outlet 1544, into
bowl refill tube 1592, through overflow tube 1692, and into bowl
1034 via flush tube 1604.
While bowl 1034 is being refilled, water also flows into tank
refill tube 1594 in order to replenish the water in tank 1520. With
flapper 1606 closes against flush tube 1604, the water flowing from
tank refill tube 1594 remains in tank 1520. Tank sensor 1694 may
indicate to controller 1708 when tank 1520 has been sufficiently
replenished with water. In an illustrative embodiment, toilet 1510
may have a capacity of approximately 1.28 gallons/flush and may be
refilled in approximately 30 seconds when flow restrictor 1562
controls the flow rate at approximately 2.5 gallons/minute.
After a flush cycle, the pressure in fill valve assembly 1540 may
be relieved to reset flush actuator assembly 1608 in preparation
for another flush cycle. In order to relieve the pressure in fill
valve assembly 1540, electrically-operable valve assembly 1548
closes such that water at inlet 1542 no longer flows into fill
valve assembly 1540. With inlet 1542 sealed, the water above piston
1638 may flow upward through flush actuator outlet 1546 and may be
released through refill outlet 1544 after tank 1520 and bowl 1034
have been refilled. Additionally, water may flow through bleed
orifice 1575 of pressure relief member 1572 in order to relieve the
pressure within fill valve assembly 1540. In one embodiment, fill
valve assembly 1540 may include an additional bleed hole to
accelerate the release of the water from flush actuator assembly
1608.
By reducing the water pressure in flush actuator assembly 1608,
diaphragm 1622, piston 1638, spring 1636, and piston rod 1620 move
upwardly due to the bias of spring 1636. This upward movement also
causes pivot assembly 1710 to move upwardly. In particular, pivot
member 1716 moves past tabs 1754 of pivot frame 1752 such that
pivot feet 1722 are again positioned above tabs 1754. Because pivot
member 1716 may be angled outwardly relative to tank refill tube
1594, pivot member 1716 is able to move past tabs 1754 without
interference in order to realign pivot assembly 1710. In one
embodiment, lower rail 1718b of guide member 1718 may contact pivot
member 1716 during the upward movement of pivot assembly 1710 in
order to realign pivot feet 1722 above tabs 1754.
Although the invention has been described in detail with reference
to certain preferred embodiments, variations and modifications
exist within the spirit and scope of the invention as described and
defined in the following claims.
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